GEAR SOLUTIONS MAGAZINE
Your Resource for Machines, Services, and Tooling for the Gear Industry
COULD SWITCHING FROM MACHINING TO GRINDING IMPROVE THE MANUFACTURING PROCESS?
ISSUE FOCUS
Chamfering/Deburring | Powder Metal Gears
COULD SWITCHING
FROM MACHINING
TO GRINDING
IMPROVE THE MANUFACTURING PROCESS?
COMPANY
PROFILE
AFC-HOLCROFT
OCTOBER 2022
OCTOBER 2022
gearsolutions.com
Vacuum Heat Treating Services
Solution Treat and Age (STA) • Annealing • Stress Relieving • Harden and Temper • Degassing • Brazing
We know high quality gears and components are
vital to performance. Our leading edge vacuum
technology and expertise provides precise control
and repeatability for consistently superior parts.
• Low Pressure Carburizing (LPC)
• Vacuum Gas Nitriding
• Vacuum Stress Relieving
• High Pressure Gas Quenching (HPGQ)
Advantages
• Uniformity of case depths
• Minimized distortion
• No IGO (Intergranular Oxidation)
• Parts returned clean, free of soot – eliminating
downstream cleaning processes
1-855-WE-HEAT-IT
solaratm.com
Eastern PA
•
Western PA
•
California
•
South Carolina
•
Michigan
FEATURES
COULD SWITCHING FROM MACHINING TO GRINDING
IMPROVE THE MANUFACTURING PROCESS?
Many high-performance industries including those in aerospace and
automotive sectors have made tremendous investments in next generation
grinding cells in order to capture the capabilities of grinding and
machining for optimizing processes.
36
ADDRESSING TRADITIONAL PROBLEMS AND
CHALLENGES WITH AM SOFTWARE
Wayland Additive has taken a pragmatic view of the development of software
associated with its Calibur3 metal additive manufacturing system.
STREAM FINISHING: THE GREEN ALTERNATIVE
TO CHEMICALLY ACCELERATED PROCESSES
Stream finishing is suitable for a variety of components, such as turbine discs,
turbine blades, blisks, servo valves, and gear wheels for the aerospace industry.
44
2 gearsolutions.com
32
INNOVATION THAT ENDURES
40
COMPANY PROFILE AFC-Holcroft produces high quality thermal
processing equipment used in the production of metal components,
while providing related aftermarket service.
ATLASBR NZE
All Bearings are not Round...
Look to us for all your Bronze Wear Plate needs!
As Cast Plate
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We offer a wide selection of Stocked Bronze
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Bronze
Bar Stock
Cast & Wrought
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October 2022 3
DEPARTMENTS
OCTOBER 2022 • VOLUME 19, NUMBER 10
8
INDUSTRY
NEWS
Reports, data, and developments to keep
you aware of what’s happening with your
colleagues in the gear-manufacturing
industry around the country and world.
Ceratizit Dragonskin multi-layer tool coating
debuts at IMTS.
New Liebherr CBN grinding discs are
small but powerful.
In this section, the premier supporter of gear manufacturing in the United
States and beyond shares news of the organization’s activities, upcoming
educational and training opportunities, technical meetings and seminars,
standards development, and the actions of AGMA councils and committees.
26
MATERIALS
MATTER
28
21
TOOTH
TIPS
American
Gear Manufacturers
Association
30
HOT
SEAT
LANE WINKELMANN
BRIAN DENGEL
D. SCOTT MACKENZIE
TACKLING EV NOISE REDUCTION
ARE MY GEARS PROPERLY
CENTERED?
NITRIDING OF STEELS
The advent and ever-increasing demand
for the quiet electric vehicle is driving the
industry to reduce transmission error and
manufacture higher quality gears.
48
PRODUCT
SHOWCASE
Understanding why the center distance
between two gears is important.
Adaptable process yields surface hardness
without the risk of distortion that
accompanies higher-temperature treatments.
54
Q&A
New products, trends, services, and
developments in the gear industry.
RESOURCES
52
MARKETPLACE
53
ADVERTISER INDEX
SCOTT KNOY
Vice President of Sales at Nidec
Machine Tool America, LLC
COVER PHOTO: SHUTTERSTOCK
Gear Solutions (ISSN 1933 - 7507) is published monthly by Media Solutions, Inc., 266D Yeager Parkway, Pelham, AL 35124. Phone (205) 380-1573 Fax (205) 380-1580 International subscription rates:
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and can be submitted to editor@gearsolutions.com.
4 gearsolutions.com
Manufacturers of:
and Universal Gear Company
1605 Precision
IndustrialPlace
Drive
2160
Auburn, CA 95603
Phone: (530) 885-1939
Fax: (530) 885-8157
October 2022 5
FROM THE
EDITOR
October offers some important
manufacturing topics
A
s we jump into fall, our October issue is filled with some interesting information to
whet your interests.
With a spotlight on chamfering & deburring and powder metal gears, our Focus articles
take a look at these important topics — both directly and tangentially.
Andrew Biro with Norton | Saint-Gobain looks at how switching to grinding from
machining can improve the manufacturing process, including when deburring becomes
an issue.
The making of powder metal gears is just one aspect of additive manufacturing, a
growing component of the gear-manufacturing process. Addressing traditional problems
and challenges with AM software is the subject of this issue’s second Focus article from
David Knight with Wayland Additive. In the article, Knight shares how the company has
taken a pragmatic view of the development of the software associated with its Calibur3
metal additive manufacturing system.
October’s final article takes a look at stream finishing, a green alternative to chemically accelerated processes that is suitable for a variety of components, including those
with complex geometries.
In this month’s Hot Seat column, Scott MacKenzie dives into the subject of the nitriding
of steels, an adaptable process that yields surface hardness without the risk of distortion
that can accompany higher-temperature treatments.
In Materials Matter, columnist Lane Winkelmann tackles EV noise reduction, a necessary step to produce a quiet electric vehicle.
And in Tooth Tips. Brian Dengel shares his insights on understanding why the center
distance between two gears is important.
You’ll find all that and so much more in this month’s issue, so be sure and spend some
quality time reading our company profile, Q&A, and industry updates as well.
I hope you enjoy it as much as we enjoyed putting it all together for you.
As always, thanks for reading!
KENNETH CARTER, editor
editor@gearsolutions.com
(800) 366-2185 x204
David C. Cooper
PUBLISHER
EDITORIAL
Kenneth Carter
EDITOR
Jennifer Jacobson
ASSOCIATE EDITOR
Joe Crowe
ASSOCIATE EDITOR | SOCIAL MEDIA
SALES
Dave Gomez
NATIONAL SALES MANAGER
Kendall DeVane
REGIONAL SALES MANAGER
CIRCULATION
Teresa Cooper
MANAGER
Jamie Willett
ASSISTANT
DESIGN
Rick Frennea
CREATIVE DIRECTOR
Michele Hall
GRAPHIC DESIGNER
CONTRIBUTING
WRITERS
ANDREW BIRO
JASON CHIN
BRIAN DENGEL
DAVID KNIGHT
LEAH LEWIS
D. SCOTT MACKENZIE
LANE WINKELMANN
Vertical Logo
CALL FOR ARTICLES Have a technical paper or other work with an
educational angle? Let Gear Solutions publish it. Contact the editor,
Kenneth Carter, at editor@gearsolutions.com for how you can share
your expertise with our readers.
6 gearsolutions.com
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OPERATIONS
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FELLOWS 20-8 GEAR SHAPERS
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Xxxxxxxx 20XX 7
INDUSTRY
NEWS
NEW TRENDS, SERVICES & DEVELOPMENTS
(ITAR) registration, Ceratizit USA provides
manufacturers with the complete application engineering, service and training support needed for maximum productivity and
cost-effectiveness.
MORE INFO www.ceratizit.com
Atlanta Gear Works adds
new manufacturers’ rep
in steel and aluminum
Ceratizit’s Dragonskin coating provides maximum protection against external influences and effectively
reduces premature tool wear. (Courtesy: Ceratizit USA)
Ceratizit Dragonskin
multi-layer tool coating
debuts at IMTS
For optimum protection against wear for
long tool life, temperature resistance, and
process reliability, Ceratizit USA Inc presented its Dragonskin multi-layer tool coating at IMTS. The high-performance coating is
based on nanolayers consisting of the appropriate combination of different coating systems and coating technologies, resulting
in maximum protection against external
influences and effectively reducing premature tool wear.
Because of the nanometer-thin layers,
Ceratizit combines different properties of
different chemical compositions to achieve
desired results. For example, the company’s
CVD cutting material grade CTCM245,
which was specially developed for machining high-alloy steels, incorporates a very
tough substrate, an Al2O3 layer, a compound
layer, and a TiCN layer to ensure the best performance. The combination provides temperature resistance to reduce thermal shocks,
which allows for higher cutting speeds along
with reduced flank and scour wear during
the machining of high-alloy steels.
To quickly and efficiently move chips
away from the tool as quickly as possible,
the after-treatment of Dragonskin produces
extremely smooth surfaces which have a positive effect on the contact friction between
chip and rake face. This further reduces
wear for even longer tool life and up to 80
percent increased overall performance.
Part of the Ceratizit Group, Ceratizit
USA designs and manufactures high quality standard and custom tooling for the metalworking industry. With headquarters in
Schaumburg, Illinois, Ceratizit USA is a solutions and service provider for many different
industry segments, including automotive,
aerospace, and energy. With a highly specialized staff, expansive product portfolio, and
an International Traffic in Arms Regulations
Atlanta Gear Works has a new working agreement with Jim McClain, general manager of
McClain Industrial Technologies, Inc., DBA
MiTek, a manufacturers’ rep that will help
the gearbox repair and manufacturing firm
spread its 34-year reputation in pulp and
paper to the steel and aluminum industries.
“At la nt a G ea r
Works is a leader in
the pulp and paper
industry,” said Cory
Mc C la i n, M iTe k
president. “We’re
looking forward to
offering their same
exceptional service
and support to our
Jim McClain
contacts in steel and
aluminum.”
In business since
1987 and headquartered in Alabaster,
A laba ma, M iTek
has extensive contacts with mechanical maintenance
decision makers
Cory McClain
in steel and aluminum rolling mills throughout the Southeast
United States. MiTek’s exclusive territory
will include Alabama, Arkansas, Louisiana,
Kentucky, Mississippi, Tennessee, Texas, and
southern Indiana.
“We were pleased when MiTek became
available to help us grow our relations with
SEND US YOUR NEWS Companies wishing to submit materials for inclusion in Industry News should contact the editor,
Kenneth Carter, at editor@gearsolutions.com. Releases accompanied by color images will be given first consideration.
8 gearsolutions.com
the steel industry,” said Craig Massa, Atlanta
Gear Works VP-Sales. “Their 30-year experience with steel will help us better serve our
steel customers.”
Even though the U.S. economy has experienced two consecutive quarters of negative
growth, this agreement comes at a time U.S.
steel capacity is expected to increase even as
prices drop, thus increasing mills’ need for
gearbox repair services.
According to ArgusMedia.com, despite
growing signs of a recession, the big four
steelmakers signaled in their latest earnings
reports that they are betting that demand
will remain steady or increase, as they pointed to persistent backlogs.
The companies say they will be ramping
up at flat-rolled mills that had been running
at sub-optimal levels and restarting other
mills that had been down for maintenance.
“Given this forecast, the timing for bringing MiTek on board is optimal and should
enable us to maintain and even grow our
market share of the industry, no matter what
happens in the wider economy,” said Massa.
Atlanta Gear Works backs its service to
the steel and aluminum industries with
the same promise on which it has built its
reputation in other industries: any make,
any model, anywhere, anytime, repaired or
reverse-engineered to equal or better quality.
25 millimeters – the size of a two-Euro coin – is the diameter of the new CBN grinding discs developed by
Liebherr-Verzahntechnik GmbH specifically for machining critical component geometries with low tool overrun.
(Courtesy: Liebherr)
The smaller the discs, the more complicated they are to manufacture.
Land, sea, air, and outer
space. When there’s no room
for failure. That’s where you’ll
find Southern Gear’s custom
precision gears at work,
both fine and medium pitch
cylindrical gears and the best
in bevel gears.
MORE INFO www.atlantagear.com
New Liebherr CBN
grinding discs are
small but powerful
Alongside diamond, CBN (cubic crystalline
boron nitride) is one of the hardest grinding materials available. CBN grinding discs
are suitable for the highest quality requirements because they are dressing-free, wearresistant, and heat-resistant. Liebherr has
developed very small CBN grinding discs
with a diameter of just 25 millimeters for
gears subject to collision and with low tool
overrun.
The company is therefore extending the
geometric process limits for internal and
external gears with interfering contours.
CBN grinding discs have a steel body,
which is electro-plated with abrasive CBN
grains. The basic steel body is break-resistant
and can be reused several times. However, the
manufacturing process is complex, especially
when making very small discs. With more
than 30 years of CBN expertise, Liebherr has
the necessary know-how to manufacture the
grinding discs completely in-house.
“In this size range, the process has no margin for error,” said Haider Arroum, head of
Keep your guard up. Look to
Southern Gear for your next
aerospace and defense
project.
There’s a Better Way.
800.248.5152 |
southerngear.com
Established in 1957
|
Veteran-Owned
|
| 3685 NW 106 St. Miami, FL 33147
ISO 9001:2015
|
AS9100D
|
ITAR Compliant
October 2022 9
INDUSTRY
NEWS
eAssistant SystemManager with E-Drive gearing from Ovako and Belix® (Courtesy: GWJ Technology)
sales for gear cutting tools at Liebherr. “And
you also have to choose the right grain size
to achieve the desired surface roughness
of the workpiece while generating as little
wear as possible, even at high rotary and cutting speeds.” Liebherr’s special design allows
for shorter and more economical grinding
processes.
The tiny discs are already being successfully used by Liebherr-Aerospace for profile
grinding of small gears for planetary gear
trains.
“They’re very happy with the results. And,
as expected, both the quality and the costeffectiveness were excellent — an important
factor in this area in particular,” Arroum said.
MORE INFO www.liebherr.com
GWJ’s calculation
of gear systems
with many innovations
GWJ Technology GmbH, calculation specialist
from Braunschweig, introduces a new version
of its calculation environment for gear systems, SystemManager, as an extension of its
well-known solutions eAssistant as web solu10 gearsolutions.com
tion and TBK as classic desktop application.
The SystemManager is a powerful and
easy-to-use extension of the GWJ solutions
eAssistant and TBK for individual machine
elements, such as shafts, bearings, connections, and various gear types, for the design
and optimization of gearbox systems, such
as multi-stage gearboxes, power-split, and
manual gearboxes, etc. In the latest version
of the SystemManager, template files or
examples with subdirectories can be structured and also created by the user.
Result graphics are no longer only available for individual load elements of a load
spectrum. It is now also possible to display
all load spectrum elements in one graphic.
This is advantageous, for example, for evaluating flank modifications by means of the
line load curve over the facewidth.
An axial offset for the gear force can be
defined in case the gears are considered as
point loads. This axial offset can also be
varied within the load spectrum. An axial
offset can be defined for masses and imbalances; in this case the distance between the
center of mass and the force element. This
also allows a center of mass outside of the
shaft geometry.
For the transfer to the individual calculations from the TBK or eAssistant, the gear
data for different calculations is now saved
for the gear element and thus kept consistent. When using 3D elastic components,
positioning has been made easier and the
mesh can be split into several subdomains,
e.g. to define different material properties.
Focusing on mechanical engineering,
GWJ Technology stands for high-quality
products and professional software development for mechanical engineering to support
engineers and designers in their daily work.
The GWJ product range of innovative calculation software is wide — from standard software for classical machine elements with 3D
CAD integration modules to the determination of whole systems up to a complex special
software for 5-axis milling of gears.
MORE INFO www.gwj.de
Mazak INTEGREX i-450H
ST emphasizes partprocessing versatility
The Mazak INTEGREX i-450H ST multi-tasking center showed its part-processing agility
at IMTS 2022. With the power of a full CNC
turning center and the versatility of a full-
The Mazak Integrex I-450H ST multi-tasking center offers single-setup production in an automation-ready
design. (Courtesy: Mazak)
function machining center, the INTEGREX
i-450H ST features a second turning spindle
(S) for DONE IN ONE® machining, along with
a milling spindle and lower turret (T) with
optional rotary tool capabilities. The configuration minimizes fixturing, part handling,
and non-cut time to boost productivity.
The main spindle incorporates a 12-inch
chuck and produces a maximum speed of
3,300 RPM from a 50 HP, 37KW 40 percent
ED spindle motor. Maximum machining
diameter is 26.380 inches (670 mm), and the
main spindle’s 4.4-inch (112 mm) diameter
bore accommodates bar stock up to 4 inches
(101 mm) in diameter. The second turning
spindle further expands processing flexibility with a 10-inch chuck, 35 HP (26 kW), and
4,000 rpm cutting, and the milling spindle
provides B-axis travel of 240° with cutting
speeds up to 12,000 RPM. An automatic tool
changer supplies the milling spindle from
a 38, 74, or 112-tool magazine. For fast part
changeovers, the INTEGREX i-450H ST features an optional auto chuck changer with
ten-jaw stockers located on each spindle and
operated via program commands.
The machine’s parallel-type twelve-tool
lower turret offers a rotary tool option with
10,000 RPM and 10 HP (7.5KW). This enables
manufacturers to employ balance cutting
with the milling spindle and lower turret,
or carry out simultaneous machining with
two tools. The turret accommodates 1-inch
(25 mm) turning tools or 1.5-inch (40 mm)diameter boring bars.
The machine enclosure, tool magazine
and optional auto jaw changer are designed
to accommodate a comprehensive range of
automation technologies, including gantry
loaders, bar feeders, and articulating robots.
The machine’s MAZATROL SmoothAi CNC
enables the INTEGREX i-450H ST to carry
out standard specialized operations such as
crankshaft inclined drilling and gear skiving.
MORE INFO www.mazakusa.com
Motion AI business
group launches
new website
Motion Industries, Inc., a leading distributor of maintenance, repair, and operation
replacement parts, and a premier provider
of industrial technology solutions, has
launched the new Motion Ai website, www.
ai.motion.com.
Announced in February 2022, the
Motion Ai business group unifies acquired
technical companies, including Applied
Machine and Motion Control (AMMC), Axis
New England/Axis New York, BRAAS, F&L
Industrial Solutions, Integro Technologies,
Kaman Automation, Meier Transmission,
and Numatic Engineering.
This new and growing website reflects
the unity of these legacy brands and showcases Motion Ai’s broad, technical capabilities with a clean, modern design that is easy
to navigate. The Resources page contains
educational videos, a blog with informational articles and a document library, including
product specs and other descriptors to help
users with their technical applications. The
Industries page narrows the focus, so users
can quickly find potential solutions to meet
their specific needs.
The Products page allows users to search
October 2022 11
INDUSTRY
NEWS
anything automation-related, from motion
control to pneumatics to sensors, while the
information on the Solutions page ranges
from automation and process to machine
vision and robotics. In these spaces, users
can easily research and source diverse products and explore Motion Ai’s wide range of
solution capabilities.
For custom assistance at any technical
level, website users can access a complete
and comprehensive team of experts, such
as engineers regarding product or system
design, and industry-segment specialists
with ultra-focused expertise.
“The new Motion Ai website provides
more innovative resources and enhanced
information for users who want to learn
anything and everything automation, robotics, and motion control,” said Aurelio Banda,
Motion’s senior vice president, Automation
Intelligence. “As an automation industry
leader, Motion Ai delivers consistent, relevant news and trends via this new website,
while allowing for rapid-response functionality. We also look forward to launching a
contemporary eCommerce platform in the
near future.”
“Blending the acquired technical brands
under Motion Ai has been a huge success,
and the resulting synergies are a major benefit for our customers,” said Randy Breaux,
president of Motion. “Now, this new website makes assistance and solutions more
accessible than ever for users who want
to optimize automation and IIoT in their
organizations.”
MORE INFO www.motion.com
www.ai.motion.com
Ecoclean solutions for
efficient and sustainable
parts cleaning
Increasing demands in component quality
and resource efficiency, as well as rising
product diversity are calling for more flexible and sustainable solutions for parts cleaning. Ecoclean is answering these requirements with several innovative parts cleaning solutions. Two of them, the EcoCvelox
and the UCMSmartLine, were presented live
at September’s IMTS event.
Regardless of the industry sector, parts
cleaning is one of the critical processes in
manufacturing today. Due to increasing
demands on component quality, new products, changed manufacturing, coating and
12 gearsolutions.com
Based on standardized modules, the plug-and-play cleaning system UCMSmartLine is a freely configurable
and cost-effective solution for various precision cleaning tasks. It can be easily adapted to changing cleaning
requirements or market conditions at any time. (Courtesy: Ecoclean)
bonding technologies as well as modified
materials, the requirements for particulate
and film-like cleanliness are constantly rising. These specifications must not only be
met in a stable manner, but also economically and sustainably. Ecoclean and UCM — the
division of the SBS Ecoclean Group specializing in high precision and ultra-fine cleaning
— are responding to these requirements with
a future-oriented range of solutions.
EcoCvelox is the all-around talent for
deburring, cleaning, and drying on a 15-second cycle. When machining components, e.g.
for hydraulic and pneumatic systems, pumps
and valves, transmissions, and other mechatronic systems, it is inevitable that burrs
are left on the component. Due to stringent
specifications regarding deburring and technical cleanliness, they have to be removed,
as well as residues of the machining media.
As a cost-efficient solution for mastering
these tasks, Ecoclean offers the innovative EcoCvelox with an integrated, highly
dynamic linear transport system.
It combines 5-axis high-pressure deburring with various part-cleaning technologies
such as flood washing, spraying, targeted
rinsing, and ultrasound and drying processes (e.g. high speed blowing and vacuum drying) in an efficient and space-saving way. The
modular design allows the user to configure
individual systems that merge high-pressure
deburring, part cleaning and drying, and to
expand them as needs evolve. The standard
modules are rated for parts measuring 200 x
200 x 200 mm which are supplied on pallets.
Processing of parts is done in cycle times of
15 seconds per pallet. A CAD/CAM interface
is integrated for quick and easy programming of high-pressure deburring — either
with a single spindle or a high-pressure turret with up to five tools.
UCMSmartLine is the smart plug-and-play
solution for precision cleaning. Companies
in a variety of industries are facing increasingly stricter requirements regarding particulate and film-like contaminations. In
order to meet these high demands, precision
cleaning machines and processes tailored to
the specific cleaning tasks are necessary. The
development and manufacturing of such
cleaning solutions is a core competency of
the Switzerland based UCM AG. With the
UCMSmartLine, the company introduces a
highly flexible and cost-effective solution.
Thanks to its cleverly designed modular
concept, highly-compact ultrasonic multichamber immersion cleaning systems can
be individually configured for preliminary,
intermediate, and final cleaning and adapted to changing cleaning tasks or market conditions at any time. The ultrasonic cleaning
modules, which are heated and fitted with a
filter circuit as standard, can also be adapted
to suit a wide range of applications. This is
enabled by the use of single, dual as well as
multi-frequency ultrasonic units. The parts
are dried by infrared radiation heat, hot air,
or under vacuum. Depending on the application, these drying technologies can also
be used in combination. Inside the plug-and
play machine, the parts are conveyed by a
standard automatic transport system with
servo drive.
MORE INFO www.ecoclean-group.net
Innovative
Grinding
& Cutting
Fluids to get
your production
into
gear
Visit us!
Jorgensen highlights
new machining filtration
line at IMTS
Jorgensen Conveyor and Filtration Solutions
spotlighted its new FlexFiltration line,
including the company’s new Flex G Series
of modular filtration systems, at IMTS 2022.
The cost-effective systems feature pre-engineered modules that ensure fast, easy, flexible filtration configurations and add value
for virtually any application.
FlexFiltration systems efficiently remove
fine chips and grinding sludge to achieve
coolant clarity down to 10 microns or less.
They are especially well suited for challenging applications with materials that range
from cast iron, steel, and aluminum to composites and plastics.
Pre-engineered base configurations and
numerous options enable quick construction of FlexFiltration systems to meet specific coolant-flow requirements. Standard,
low-profile, and stainless-steel tanks make
these systems ideal for machine tool OEMs
and regular end users. Other modular
options that complete a system include high-
GEARING AHEAD TO MEET INDUSTRY’S
DEMAND FOR PRECISION
– SERVING –
Aircraft • Aerospace • Actuation
Instrumentation • Optic
Robotics • Radar • Medical
Marine • Defense • Experimental
Prototype • Production
Hi-Performance Automotive
Precision Gear Products (up to AGMA Q14):
Spur Gears, Helical Gears, Worm Gears, Anti-Backlash Gears, Cluster Gears, Clutch Gears,
Face Gears, Planetary Gears, Gear Assemblies, Gear Boxes, Bevel Gears, Miter Gears,
Metric Gears, Internal Gears, Idler Gears, Gear Rack & Pinion, Worms, Wormshafts,
Splines, Spline Shafts, Serrated Shafts.
CNC Thread Grinding
Nadcap Accredited: Heat Treatment, Induction Hardening, Passivation
STD Precision Gear & Instrument, Inc.
318 Manley St. • W. Bridgewater, MA 02379
(847) 531-8501
www.oelheld.com
sales-us@oelheld.com
(888) STD-GEAR or (508) 580-0035
Fax (888) FAX-4STD or (508) 580-0071
E-mail info@stdgear.com • Web site: www.stdgear.com
October 2022 13
INDUSTRY
NEWS
pressure pumps, auxiliary pumps, tramp oil
skimmers, coolant chillers, heat exchangers,
liquid level sensors, temperature sensors,
and the ability to control/interface with
existing pumps and other equipment.
Jorgensen’s Flex G Series systems feature
gravity media filters. The gravity media
filtration option is the first one available
in the FlexFiltration product line. Gravity
filters are offered in 30, 60, and 90 gpm
options and come standard with low media
roll detection, no media alarm sensor, and
automatic roll advance. A variety of different
disposable cloth medias are also available
based on specific applications. Additional
primary filtration options including bag
filtration, cyclonic, and permanent media
types will soon be offered.
MORE INFO www.jorgensenconveyors.com
Regal Rexnord debuts
device to protect
gearboxes from moisture
Regal Rexnord Corporation, a global leader
in the engineering and manufacturing
of high-efficiency electric motors, power
transmission products, and industrial powertrains, announces the launch of its new
AirMax® Pro Smart Breather, a connected
device that protects industrial gearboxes
from moisture and particles.
A leading cause of gearbox failure is lubricant contamination or corrosion inside the
box as a result of intrusion of moisture or
particles, leading to machinery failure
caused by abrasion, erosion, fatigue, and
corrosive wear. The cost of removing particles and moisture is also 10 times the cost
of prevention.
Keeping the inside of the gearbox clean
and free of these harmful materials is therefore critical to a long life of operation. In
addition, being able to monitor contamination levels inside the gearbox is essential to
the efficient and safe operation of plant and
equipment.
Regal Rexnord’s new AirMax® Pro Smart
Breather is specifically designed to protect
gearboxes and ensure they operate at maximum efficiency in the harshest of environments, such as grain handling. It extends
the life of industrial lubricants by preventing contamination with desiccant breathers,
removes contaminants with filtration systems, and detects lubricant problems with
visual oil analysis.
14 gearsolutions.com
Regal Rexnord’s new AirMax Pro Smart Breather keeps industrial gearboxes running longer by using Perceptiv
connected technology to monitor gearbox status in real time. (Courtesy: Regal Rexnord)
In addition, the breather detects and
records any unusual spikes in humidity
and water ingress by integrating with Regal
Rexnord’s Perceptiv™ connected technology, which uses cloud-based technology to
track, report, communicate and share performance data.
This connectivity enables users to monitor the status of their equipment through a
variety of modules, sensors, and other connected products. Early detection of system
upsets, avoidance of equipment failures,
and unplanned downtime saves the operator money while maintaining operational
efficiency.
The AirMax® Pro Smart Breather is particularly powerful when installed in Regal
Rexnord’s gearboxes, such as its Falk V-Class
and Planetgear drives, which are specifically
designed for use in the harshest industrial
environments, including wood products and
mining where environmental impacts can
affect the life of a gearbox.
MORE INFO www.regalrexnord.com
Rego-Fix showcased
precision, high-accuracy
metrology at IMTS
Rego-Fix demonstrated the precision of its
innovative, easy-to-use 3D-EdgeMaster precision centering devices and MasterBar test
arbors at IMTS. Rego-Fix developed these
products to help shops improve production
quality and track machine tool performance
with measurement devices that uphold the
company’s high standards of precision.
3D-EdgeMaster measuring technology
continues the Rego-Fix tradition of meeting
the challenges of process reliability with fast,
precise probing of reference edges, setting
the zero point, and measuring with repeat
accuracy of ≤ 0.01 mm. Available in both inch
and metric versions, the 3D-EdgeMaster is
shock- and splash-proof in accordance with
IP 67 regulations. A predetermined breaking
point in the easy-to-replace ceramic probe
insert protects the device mechanism. Shops
can set the X and Y axes to adjust runout,
calibrate the measuring path, center the
machine axis, and determine the bore center.
To shorten setup time, improve precision,
increase CNC quality, and minimize scrap
costs, Rego-Fix measuring technology also
includes MasterBar test arbors for machinespindle calibration. After a thorough cleaning of the inside of the spindle, operators
chuck the MasterBar arbor and measure
the arbor runout close to the spindle nose
(~50mm from the interface) with a 1 µm
or 2 µm scale dial indicator. Shops also can
check runout at the bottom of the arbor for
comparison to the spindle manufacturer’s
specifications, test parallelism and verify
spindle alignment after a crash. The arbors
are available in ST, CAT, BT+40, HSK-A, HSKE, and ATC-E interfaces, in lengths from 350
mm to 70 mm and diameters from 40 mm to
10 mm, depending on interface size.
Rego-Fix supplies its MasterBar test arbors
in custom foam packaging that supports
their entire length, to preserve straightness
and measurement accuracy. The products
meet the same standards that Rego-Fix
applies to its tool holding, with cylindricity at a maximum of 2 µm along the entire
length and runout from the cylindrical part
of the tool to the taper of under 3 µm.
All Rego-Fix metrology devices incorporate a laser-marked QR code that loads the
Rego-Fix website to access technical information about the specific tool and its inspection
certification.
Klingelnberg officially
inaugurates new
machining hall
After just ten months of construction, the
new assembly hall and connected logistics
center was officially inaugurated on the
company premises of Klingelnberg GmbH
in Winterhagen-Hückeswagen in September.
Covering a total area of 8,000 square meters
and located at the future Gustav-Adolf-
Klingelnberg-Straße 1, the new facility is
where Klingelnberg is now building large
gear machines in particular, which are destined for use in the wind power industry,
among others. New office workspaces with
a dedicated canteen have also been built and
will be ready for move-in by 2023 at the latest.
The challenging project set on a tight
timeline was completed in just ten months.
The groundbreaking ceremony took place
in December 2021. Thanks to modern building and plant engineering practices, optimal
MORE INFO www.regousa.com
Jergens Inc. completes
sale of subsidiary
JIS to PT Solutions
Jergens Inc., a leading manufacturer of standard tooling components, fasteners, hoist
rings, vises, and other workholding equipment, has formally completed the sale of
subsidiary JIS Distribution, LLC to diversified holding company PT Solutions.
“Today’s announcement is a bittersweet
one, but marks an exciting turning point in
the story of our family business,” said Jack
Schron, president of Jergens Inc. “As we look
to the future of this company, it is clear that
our greatest opportunities lie in manufacturing — the original roots of our business.”
This transfer of ownership comes as the
result of the strategic vision that seeks to
align the company’s focus on its core manufacturing business. Founded in 1942, Jergens’
innovative pioneering of lean manufacturing served to quickly expand the company
into a multifaceted integrated service line
complete with its own distribution division
in the form of JIS. In 2020, family shareholders reached a decision to divest from their
distribution business and concentrate on
growing the company’s already strong position in the manufacturing market.
Schron reinforces that the family-owned
company and its 400 employees remain committed to the collective mission of helping
customers achieve leaner, more profitable
manufacturing efficiency.
“Our shareholders remain committed to
our corporate family and to our customers.
We will continue to build this company on
the values we demonstrate every day and will
be there to support and serve our customers
with the very best service,” Schron said.
MORE INFO www.jergensinc.com
A PERFECT MESH
American ingenuity, service and support teamed
with Japanese efficiency, quality and technology.
100+ Years of Manufacturing Gear Hobbing Machines
8 Models of Machines from 50 to 1000mm
KPS 201 GEAR
SKIVING MACHINE
KN 152 CNC
GEAR HOBBER
70+ Years of Manufacturing Gear
Inspection Machines
Machine Models to 850 OD Capacity
CLP-35DDSF
GEAR TESTER
GTR 25 DOUBLE
FLANK GEAR ROLLER
Phone: 586-329-3755 \ Fax: 586-329-3965
rodney.soenen@involutegearmachine.com \ www.involutegearmachine.com
October 2022 15
INDUSTRY
NEWS
From left, Sascha Becker, head of property management; Philipp Kannengießer, chief operating officer; Dietmar
Persian, mayor of the town Hückeswagen; and Christoph Küster, chief financial officer, check out Klingelnberg’s
new assembly hall. (Courtesy: ©Klingelnberg)
operating conditions were created: The halls
will be fully air-conditioned and equipped
with two bridge cranes — one with a 25-ton
working load limit and one with a 40-ton
working load limit — and 10 wall-mounted
traveling cranes, each with a 3.5-ton capacity.
This means that even the most sensitive and
heaviest machines can be assembled there.
From the planning and realization
phases onward, energy efficiency and environmental protection were a key focus. The
hall is built to meet the climate-efficiency
requirements according to Kf W 55 — a climate standard that is not particularly common for industrial buildings at present.
The machine hall officially commenced
operations on September 12, with the start of
assembly of the Höfler RAPID 1600 and VIPER
500 cylindrical gear grinding machines. The
Höfler Cylindrical gear grinding machine
RAPID-series is specialized for workpieces
up to eight meters in diameter and 100 tons,
while the Höfler cylindrical gear grinding
machine VIPER 500 is designed for component diameters up to 500 mm and is therefore ideal for small to medium batches. With
its extensive machine portfolio covering a
range of requirements, Klingelnberg is able
to meet the needs of just about every sector
and industry.
“With a volume of EUR 20 million, this
was the largest single investment we made
in recent years,” said Christoph Küster, chief
16 gearsolutions.com
financial officer of the Klingelnberg Group.
“In this day and age, it’s not easy to complete
such a complex construction project within
budget and on schedule. On behalf of the
management, I would like to thank all our
employees who actively supported this project and ensured it was completed on time.
The project was an important component
for the future-preparedness of our location. By expanding our capacity, we created
new jobs in Hückeswagen. Our company
already has over 150 years of history in the
Oberbergischer Kreis district, and we are
thrilled to continue making history in this
tradition- steeped location.”
To celebrate the inauguration of
the new assembly hall, Klingelnberg’s
Management Board invited all employees
at the Hückeswagen location to a meal
onsite. Dietmar Persian, mayor of the town
of Hückeswagen, also visited Klingelnberg.
MORE INFO www.klingelnberg.com
A green future designed
by Seco/Warwick
and GreenIron
The Seco/Warwick Group, a global manufacturer of metal treatment equipment,
has signed an agreement with the Swedish
company GreenIron H2 AB for the delivery
of a series of furnaces for fossil-free metal
production from ore, residuals, and waste
recycling.
The new line of reduction furnaces, based
on the technology provided by GreenIron,
is in response to climate change and the
urgent need to reduce CO2 emissions and
create energy and resource-efficient business models.
“The long-term agreement provides
for the delivery of a series of equipment.
Cooperation in this technology area will
provide us with development and cooperation in the area of pro-ecological solutions,
which is in line with the company’s mission.
With this new technology, together with
GreenIron, we are contributing to global ecosystem protection,” said Sławomir Wożniak,
CEO of Seco/Warwick Group.
The furnaces ordered by GreenIron will
be used to recycle oxidized metals without
emissions. They will therefore directly contribute to CO2 emission reduction on an
unprecedented scale. Each furnace has the
capacity to reduce emissions by 56.000 metric tons/yr. The technology, whose originator
and patent rights owner is GreenIron, is a
unique solution that will help many enterprises implement “green” solutions and
function with the natural environment.
“We are happy to work with Seco/Warwick
on this exciting journey toward a more
energy and resource-efficient industry with
zero emissions,” said Edward Murray, CEO
of GreenIron. “We feel that our partnership
is a great foundation for rapid growth and
a positive impact on emissions and climate
change. GreenIron has high ambitions in
regard to CO2 reduction, starting with the
first furnace, delivered from Seco/Warwick,
and the subsequent first shipment of commercial fossil-free iron in 2023.”
“It is also an opportunity for Seco/
Warwick, because together with GreenIron
we are creating a production line of completely new furnaces,” said Wożniak. “For
the first time, we are working closely with
an external partner with technology that
comes from outside of our organization. Our
task in the project is to build effective solutions and deliver them on time.”
Seco/Warwick supports ecological solutions making the heavy industry environmentally friendly. The new furnaces in the
production line manufactured in cooperation with GreenIron, are units that have not
been available on the market so far. Their
great value is the fact that they contribute
to carbon dioxide reduction, as well as sig-
nificantly reducing the costs of recycling
post-production residuals and waste.
The metals are extracted from ore or recycled without the release of fossil gases. Iron
oxide (magnetite, hematite, wustite) is converted to pure iron by the hydrogen reduction process. In traditional technology, this
process takes place in coke furnaces, which
results in CO2 emissions. In the GreenIron
furnaces, CO2 emissions are zero.
Reduction furnaces will be available to
companies throughout the entire lifespan
of iron and other metals — including mining, steelmaking, milling stations, foundries,
metal workshops, and heavy ashes from
incinerators. With GreenIron and Seco/
Warwick, this waste will be given a second
life and can be reused as pure steel or iron.
These will not be the first solutions
from the Seco/Warwick brand that support
“green technologies.” Another example is
ZeroFlow® gas nitriding technology allowing users to reduce technological costs by up
to several dozen percent. Another solution —
Vortex® (aluminum coil annealing furnace)
reduces the component processing time by
up to 30 percent compared to other available technologies. This reduces both energy
consumption and emissions. On the other
hand, Pit-LPC (pit furnace) technology shortens process time thus reducing energy and
gas consumption. This directly decreases
production costs, while improving the quality of results compared to traditional technology. But in the case of Seco/Warwick, taking care of the environment does not apply
only to its products. Sustainable production
and ecological innovation are part of a longterm strategy.
GreenIron H2 AB is a privately held
company with patented and proven energyefficient technology to reduce metalloxides
to pure metal. The process is suitable for
the creation of metals from ore, residuals,
and waste. The technology is hydrogen
based with only water as the process emission. When using the GreenIrons process
in conjunction with a steel mill users can,
without any CO2 emissions, create prime
iron-based metals for reintroduction to
the steelmaking process from the waste
and residuals formed in the steelmaking
process. GreenIron enables a fully circular resource usage on site. GreenIron has a
strong focus on minimizing CO2 emissions
and strives to create circular business mod-
els with minimized CO2 emissions and high
resource efficiency.
MORE INFO www.secowarwick.com
www.greeniron.se
Latrobe Magnesium
awards contract
to Tenova Technology
Tenova, a leading developer and provider of
sustainable solutions for the green transition of the metals industry, was awarded
a contract by Latrobe Magnesium Limited
(LMG), a company based in Australia. The
scope of work is the engineering, supply, and
supervision of the Magnesium Oxide (MgO)
production plant at Latrobe Valley, Victoria,
Australia, a demonstration plant using a
world-first process of combined hydromet/
thermal reduction.
As part of the first phase of the project,
Tenova’s scope of supply will include a magnesium oxide (MgO) plant, with spray roaster
technology, with a production capacity of
300 kg/h.
KISSsoft AG/Gleason Sales
Brian P. Stringer
Phone (585) 494-2470
info@kisssoft.com
YOU’VE GOT THE PRODUCTS.
YOU’VE GOT THE SERVICES.
NOW, LET US SHARE YOUR STORY.
Gear Solutions wants to make sure the best
possible audience knows your company.
Through our print, online, and social media
presence, our experienced staff can get
your message to an industry that wants
to know what you can do.
NEW
Release
2022
KISSsoft Features
▪ Influence of flank waviness on transmission error
▪ Tooth root fatigue strength from time series
▪ Bearing contact stress with modified raceways
▪ Bearing inner geometry from Schaeffler and Timken
▪ Optimized bolt module interface
Trial version requests via www.kisssoft.com
To learn more, contact national sales manager
Dave Gomez at dave@gearsolutions.com
or call 800.366.2185 ext. 207
October 2022 17
neu_GearSol_KISSsoft_Release2022_92_25x123_83mm.indd 1
22.07.2022 09:39:35
INDUSTRY
NEWS
The demonstration plant will initially
have capacity of 1,000 metric tons of magnesium (Mg) metal per year, and in the second
stage, LMG intends to develop a commercial
scale operation with an envisaged production capacity in the range of 10,000 to 40,000
metric tons per annum of magnesium metal.
Thanks to its world-first patented hydrometallurgical extraction and thermal reduction process, the plant will harvest magnesium metal from a fly ash resource — a waste
stream from brown coal power generation.
The project is at the forefront of environmental sustainability as it converts nearly
100 percent of the resource into valuable
commodities. The released CO2 emissions
are approximately 50 percent less than comparable magnesium production plants.
“Demand for magnesium worldwide is
strong,” said David Paterson, chief executive
officer at LMG. “It has the best strength-toweight ratio of all common structural metals
and is increasingly used in the manufacture
of car parts, laptop computers, mobile phones,
and power tools. Currently, the Latrobe
Valley contains 25 million tons inventory of
fly ash, that is why it so important for us to
have a reliable partner in this project.”
“Through many years of experience and
continuous improvement of pyro hydrolysis
process, Tenova is able to meet specific customer requirements. The positive and constructive cooperation with Latrobe during
the development phase of the magnesium
production facility was a decisive factor
to now deepen this work in the course of
realization,” said Gregor Kappacher, branch
manager at Tenova Austria, the competence
center for spray roaster technology. “The
project is of paramount importance for
Tenova, because it opens positive future
perspectives and is in line with our effort
towards achieving a sustainable industry.”
The first magnesium is forecast to be produced in 2023.
MORE INFO www.tenova.com
Nord Drivesystems to
showcase high-efficiency
drive solutions
Nord Drivesystems will exhibit new,
intelligent drive solutions at PACK EXPO
International October 23-26 in Chicago.
Nord designs, engineers, and manufactures
complete solutions focused on energy efficiency, reliability, and versatility. Their
modular product portfolio offers more than
20 million standard combinations of gear
units, motors, and control products that fit
precise needs without costly custom components.
PACK EXPO attendees can find these
efficient drive solutions on display at Booth
N-4974.
IE5+ permanent magnet synchronous
motors (PMSM) deliver next-level efficiency and performance from 0.5 – 5.0 HP. Two
compact designs are available — a hygienic
version with smooth surfaces for washdown applications (TENV design) and a
ventilated version for optimized heat dissipation with high overload capacity (TEFC
design). IE5+ motors follow Nord’s modular
concept to accommodate a wide range of
packaging applications.
Nord’s nsd tupH Sealed Surface
Conversion System provides a smooth, easyto-clean surface that is resistant to corrosion,
acids, and alkalis, and unlike paint, won’t
blister or flake. The treatment is applied to
18 gearsolutions.com
Nord will feature their IE5+ product portfolio
consisting of DuoDrive integrated gear unit/motors,
IE5+ ultra-high-efficiency synchronous motors, and
NordAC ON/ON+ intelligent variable frequency drives
at PACK EXPO. (Courtesy: Nord Drivesystems)
aluminum-alloy housings — permanently
transforming the metal’s physical properties
and creating a surface that is up to seven
times stronger than the original. When compared to stainless steel, nsd tupH provides
a lightweight, cost-effective alternative that
is more readily available in a variety of gearmotor options. In addition to this innovative
wash-down surface treatment, Nord units
featuring nsd tupH are also equipped with
stainless steel shafts, hardware, and special sealing rings to further protect against
unwanted moisture entering the gearbox
and damaging components.
The DuoDrive design integrates a highefficiency IE5+ motor with a single-stage
helical gear unit in one, compact housing.
This solution combines the benefits of Nord’s
modular product system with the possibility of reducing system variants through constant torque over a wide speed range. These
drives deliver performance of 0.5 – 4 HP and
produce an extremely high system efficiency of up to 92 percent — making them wellsuited for packaging systems. DuoDrive also
features high power density, quiet operation,
and simple plug-and-play capabilities for fast
commissioning.
NordAC ON/ON+ variable frequency
drives offer intelligent control of packaging
systems with integrated PLC functionality,
integrated multi-protocol Ethernet interface,
and POSICON positioning. They are compatible with operation of asynchronous and synchronous motors and can be wall-mounted
or motor-mounted for versatile installation
arrangements to meet application needs.
These VFDs deliver performance up to 1.27
HP and feature full Plug-&-Play capabilities
for a reliable, economic solution within IIoT
environments.
The complete LogiDrive® solution provides an energy-efficient, standardized, and
service-friendly drive system that is ideal for
high-volume warehousing, manufacturing,
and packaging systems. The choice of IE4 or
IE5+ Permanent Magnet Synchronous Motor
(PMSM) technology enables drives to maintain high efficiency even within partial load
ranges and at low speeds. LogiDrive also
minimizes total cost of ownership (TCO)
throughout service life, providing a faster
return on investment, and maximizing system availability. When Nord gear units and
motors are paired with NordAC LINK VFDs
as a part of the LogiDrive system, a wide
speed range with high-precision regulation
is achieved to deliver automation for stacker
cranes, automated guided vehicles, a wide
variety of conveyors, and more.
The LogiDrive solution consists of:
 High efficiency 2-stage bevel gearbox.
 IE4 or IE5+ permanent magnet synchro-
nous motor.
 Decentralized variable frequency drive.
 Power plug connector.
 M12 connectors.
 Incremental encoder.
 Pre-assembled cables.
 High overload capacity.
 Standardized hollow shaft diameters.
MORE INFO www.nord.com
FIXTURE AND PRESS HARDENING SYSTEMS
Fixture hardening, press hardening, hot forming and hardening
• Fixture hardening
• Press hardening
• Hot forming and hardening
• Press automation
(Picture:
Turn-key hardening plant
for synchronizing parts)
PRESSES, PRESS SYSTEMS AND FULLY-AUTOMATIC SYSTEMS
www.wickert-usa.com
October 2022 19
GEAR SOLUTIONS
MEDIA PORTAL
Gear Solutions’ online portal is your gateway to social media
news and information resources from manufacturers and
service providers in the gear industry. You’ll find links to
social media as well as webinars, blogs and videos.
This quick-and-easy resource is just a click away at
gearsolutions.com.
20 gearsolutions.com
American
Gear Manufacturers
Association
Leah Lewis
Jenny
Blackford
Vice President
AGMA
Director,of
Communications
Meetings
& Events
AGMA
IMTS is important, but MPT Expo is still
the best place for gear manufacturers
I
am writing this while I put my feet up
iar faces in the North Hall, with members
from walking more than 20,000 steps
surrounding us in this small gear section
of the show. It felt like home seeing our suptoday. I had to take a moment before
pliers and manufacturers walking around
beginning as my mind was over-stimulated from meeting what felt like hundreds
and networking. It also felt a little bit like
of people earlier and as someone who runs
we were all stuck in a small apartment of
a tradeshow for AGMA, I somehow felt like
this bigger city that is the show. I looked
I had never seen one before — I experienced
around and realized that even with the flow
IMTS for the first time today.
of traffic, our members had to be found.
So, my message after all this is to my gearThose of you who know, know what I am
ing friends: Don’t go to a place where you
talking about. Those of you who have yet to
have to be found, come to a show where you are the star — a show
visit this impressive mammoth of an event, should at least go once if
where you are the mansion on the street that is the show. IMTS
you are in manufacturing. My colleagues and I go to this show for the
is glorious for what it is, but it isn’t a show for the gear industry,
purpose of sharing our publications and for meeting our members
MPT Expo is.
that exhibit and attend. Many of our supplier members have exhibited for years at IMTS, and we always want to show our support for
Join us next year in Detroit, Michigan, October 17-19, 2023, for
them and their businesses.
the MPT Expo.
IMTS boasts an incredible footprint with more than 1 million
If you’d like to exhibit, contact Christine von Steiger at 703-706square feet and an attendance of close to 100,000 people this year. The
8252 or agmasales@ntpevents.com.
booths span across five different buildings
internally with multiple floors. Some exhibits have two levels and offices larger than
our personal booth at our own tradeshow,
Motion+Power Technology Expo (MPT Expo).
I came in with a goal of understanding the
industry at a deeper level, seeing the modern
technology and digitization of manufacturing and hopefully knowing how this (somewhat) competitor of a show is different than
ours. In one day, I learned a lot.
This is a David-and-Goliath situation.
MPT Expo does not compete with IMTS;
we are two different shows, but each is as
powerful in what we offer to the industry.
Walking around all the different buildings
and talking with associates selling out of
their 10,000-square-foot booths, I realized
that MPT Expo doesn’t want to be IMTS.
Sure, the size, the attendance, the money, it
all demonstrates the hard work and dedication that AMT puts into this show, but with
representing such a niche sector (gearing),
would I want just a small pavilion, when I
can have my own show?
IMTS is glorious for what it is, but it isn’t a show for the gear industry, MPT Expo is. The Motion+Power
The AGMA media booth was with familTechnology Expo will be in Detroit in October 2023.
October 2022 21
Upcoming Training Webinars & Seminars
Robot Simulation: Make the Most
of Your Investment in Automated
Manufacturing
October 5 | Webinar
Manufacturers in every industry are adopting robotic automation at an accelerating
rate. The investment required for automation is often significant and comes with a
host of options. What type or size of robot
should be selected? What throughput can be
achieved through this new system? Will the
work cell fit into my production line? All of
these questions can be answered with robot
simulation software. This multi-function
tool is invaluable in modeling complicated
manufacturing systems. In addition to
explaining how robot simulation software
can be used, this presentation will provide
case studies that demonstrate how simulation early in the project can avoid later problems with robot integration.
Operator Hobbing & Shaping Cutting
October 5-6 | Chicago, Illinois
Learn and understand fundamentals of gear
manufacturing. Acquire knowledge and
understanding of gear nomenclature, hobbing and shaping of spur and helical gears,
and splines. Learn and understand hobber
and shaper machine set-up, as well as geartooth element inspection. Understand the
manufacturing process before gear-tooth cutting, as well as postcutting processes. Apply concepts to further finishing processes, I.e.
heat treat, gear tooth shaving, and grinding and/or skiving. Gain
knowledge to establish a solid foundation for all basic gear manufacturing.
How to Interpret a Gear Inspection Chart
October 13 | Virtual Course
This half-day online seminar is intended to provide a thorough
understanding of the information contained within a typical gear
inspection report. Specifically, we will look at the contents and meaning of the information contained within the gear charts, as well
as the techniques used by the gear-measurement system to assess
gear quality. An explanation of basic gear measurement techniques,
how measurement equipment and test machines implement these
techniques, and how to interpret the results from these basic measurements will be covered. We will also discuss how to interpret the
results and what corrective actions may be considered if the quality
of a particular gear is unsatisfactory.
American
Gear Manufacturers
Association
22 gearsolutions.com
Gear Materials
October 18-20 | Chicago, Illinois
Learn what is required for the design of an optimum gear set and
the importance of the coordinated effort of the gear-design engineer,
the gear metallurgist, and the bearing system engineer. Investigate
gear-related problems, failures, and improved processing procedures.
Unpacking the CHIPS Act and Related Funding
Legislation and Looking Ahead to the Mid-term Elections
and Their Impact on Trade Policy
October 19 | Webinar
Summer 2022 was a busy time in Washington with Congress passing several important new funding bills that direct hundreds of
billions of dollars of funding and incentives to a range of industries.
Join us as we unpack what’s in these new laws, what it means for
you, your company, and the U.S. economy, and how to respond to
protect your interests and grow your business. We’ll also cover the
latest predictions on how the 2022 midterm elections may shape
U.S. trade and investment policy for the next two years.
Involute Spline Design & Rating
October 26-27 | Virtual Course
This course will address both geometry and rating of involute splines
of various types. The types of spline joints and their applications
will be discussed. Spline configuration variations, including half
depth, full depth, and special function designs will be addressed.
Both fixed and flexible spline configurations will be examined in
terms of usage and design. Lubrication methods, including grease,
oil bath, and flowing oil, as well as coatings appropriate for various
spline applications are examined. Shear and compressive stress rating methods are discussed with analyses methodology presented in
both equation and graphical methodology via various rating charts.
Fall Technical Meeting
Sessions and Paper Titles
The 2022 Fall Technical Meeting (FTM) will feature the burgeoning
research in the gear industry, shared by researchers through highly
technical presentations over the course of three days.
Session 1 – Efficiency, Lubrication, Noise, and Vibration
October 17 | 1-5 p.m.
 Development of a New Test Method to Investigate the Scuffing
Load Carrying Capacity of Hypoid Gear Oils.
 Mechanical Power Loss of Spur Gears Subject to Various Surface
Finish Pairings.
 Aspects of Gear Noise, Quality, and Manufacturing Technologies
for Electro Mobility.
 Sound Intensity Analysis of Straight Bevel Gears Finished by
Using AFF Process.
 Optimizing the Operational Behavior of Double Helical Gears
by Means of an FE-Based Tooth Contact Analysis.
Session 2 – Inspection and Analysis
October 18 | 8 a.m.-noon
 In Process Measurement and Compensation for Manufacturing
Skiving Cutters.
 Methods for Checking the Profile of the Path of Contact of
Involute Gears.
 Finding the Right Task for Optical Gear Metrology.
 Cross-Correlation Analysis Among Tooth Profile and Helix
Deviations.
 Special Presentation: Noise Analysis for e-Drive Gears and
In-Process Gear Inspection.
Session 3 – Manufacturing
October 18 | 1:10-5 p.m.
 A New Low Pressure Carburizing Solution in a Pit vs. Traditional
Pit Carburizing Methods.
 Mathematical Model of a Straight Bevel Gear on the Straight
Bevel Coniflex Generator and Gear Flank Correction.
 Power Skiving Tool Offsets and the Feasibility of Using a
Calculator for Manipulating the Resulting Geometry.
 Closed Loop for Gears: Some Case Studies.
 Modern Green and Hard Machining of Double Helical Gears.
Session 4 – Application, Design, and Rating
October 19 | 8 a.m.-noon
 Effect of Tooth Root Fillet Design on Tooth Root Stress in Short
Fiber Reinforced Plastic Gears.
 Investigations on the Tooth Root Bending Strength of LargerSized Induction Hardened Gears.
 On the Potential of High-Ratio Planetary Gearboxes for NextGeneration Robotics.
 A Model for Considering Wheel Body Deformation in Tooth
Contact Load Distribution.
 A Decomposition of the Torsional Stiffness of a Worm Gearbox
into Individual Components.
 Unconventional Gear Profiles in Planetary Gearboxes.
Session 5 – Testing and Failure
October 19 | 1:10-5 p.m.
 Implementation of a Gear Health Monitoring System on a Power
Recirculating Test Rig Using the Average Log Ratio (ALR) Algorithm.
 Enhanced Calculation Method for Tooth Flank Fracture Risk
with Consideration of Tensile Residual Stresses in Larger Material
Depths.
 Experimental Evaluation of Wind Turbine Gearbox Structural
Models Using Fiber Optic Strain Sensors.
 Test Rig for Crowned Spline-Joints with Optimized Surface
Treatments Under Misaligned Conditions.
 Results of ISO/TS 6336-22 Evaluating Full Contact Zone.
Join us to explore the latest methods and cutting-edge technologies in gearing today! Visit agma.org/events/fall-technical-meetingftm for complete information.
Join an AGMA Technical
Committee Today
Shape the gear standards of tomorrow, today. Join more than 300
of your gear industry colleagues by volunteering on at least one of
AGMA’s 23 technical committees. The expert knowledge in AGMA’s
current catalog of more than 100 documents boosts American and
worldwide business. AGMA technical committees are also your vehicle to participate in development of more than 50 ISO gear standards,
as many AGMA committees have a secondary function as technical
advisory groups to ISO.
To join a committee, all you need to do is be a member of AGMA
and email us your interest at tech@agma.org.
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October 2022 23
CALENDAR OF EVENTS
OCTOBER
Whether you’re looking for technical education, networking opportunities, or a way for your voice to be heard
in the standards process, AGMA has something to offer you. If you would like more information on any of the
following events, visit www.agma.org or send an email to events@agma.org.
October 17-19 — Fall Technical Meeting — Rosemont, Illinois
October 18-20 — Gear Materials Course — Chicago, Illinois
October 25 — Metallurgy & Materials Committee — WebEx
November 2-3 — Operator Precision Gear Grinding — Chicago, Illinois
November 2 — Emerging Technology Webinar — IIoT with Tulip Webinar
NOVEMBER
November 8 — Gear Accuracy Committee — WebEx
November 8 — TDEC Meeting — WebEx
November 10 — Helical Gear Rating Committee — WebEx
November 15-17 — Gear Failure Analysis — Ranken Technical College
November 16 — Helical Enclosed Drives High Speed Units Committee — WebEx
November 16 — Trade Webinar – U.S. Defense Policy, the FY 2023 National Defense Authorization Act, and impact on
funding/government contract/investment opportunities for bearing and gear companies — Webinar
DECEMBER
November 30 — Wormgearing Committee — WebEx
December 6 — Design Basics for Spur and Helical Gears — Virtual Course
December 7 — Emerging Tech Webinar – BLOCKCHAIN Discussion with Notoros.io — Webinar
December 8 — Nomenclature Committee — WebEx
December 13 — Aerospace Committee — WebEx
STAFF
Greg Schulte: Chairman
Bonfiglioli USA
Michael Cinquemani: Treasurer
Master Power Transmission
Michael McKernin: Chairman, BMEC
Milans Machining and Gear Manufacturing
Todd Praneis: Chairman, TDEC
Cotta Transmission Company, LLC
John Cross: Chairman Emeritus
ASI Drives
Matt Croson: President
Amir Aboutaleb: VP, Technical Division
Jenny Blackford: VP, Marketing
Randy Stott: VP, AGMA Media
BOARD OF DIRECTORS
EXECUTIVE COMMITTEE
AGMA LEADERSHIP
Craig Burriss: Industrial Gear Group
Brian Coclich: CGI, Inc.
Greg Estell: The Estell Group LLC
Adam Gimpert: Helios Gear Products
Joe Goral: Bourn & Koch, Inc.
Mushtaq Jamal: Bevel Gears India, Pvt, Ltd.
Michelle Maddox: B&R Machine and Gear Corp.
Scott Miller: Caterpillar, Inc.
Eric Van Rens: Schafer Industries
Robert Rye: Cincinnati Gear Co.
Nicole M. Wolter: HM Manufacturing
Scott Yoders: Liebherr Gear Technology, Inc.
General requests: webmaster@agma.org | Membership questions: membership@agma.org | AGMA Foundation: foundation@agma.org
Technical/Standards information: tech@agma.org | MPT Expo information: mptexpo@agma.org
24 gearsolutions.com
Technical Education.
Career Development.
International Networking.
Log on to
www.stle.org/
annualmeeting
for registration and
hotel information.
77th STLE Annual
Meeting & Exhibition
Long Beach Convention Center
Long Beach, California (USA)
Whether you work in the field
or lab—in industry, academia or
government—STLE’s Annual Meeting
has programming designed
specifically for you. Please join your
peers from around the globe for five
unique days of technical training and
industry education that could change
your career.
LONG BEACH
May 21-25, 2023
Program Highlights:
• 500 Technical Presentations and Posters
• 13 Lubrication-specific Education Courses
• New Sustainable
Power
Track
LO
N GGeneration
BEAC
H
• Special SessionMay
on 21-25,
AI and2023
Machine Learning
• Discussion Round Tables – An Ideation Event
• Trade Show
• Commercial Marketing Forum
• Business Networking
LONG BEACH
May 21-25, 2023
Society of Tribologists and Lubrication Engineers
840 Busse Highway, Park Ridge, Illinois 60068 (USA)
P: (847) 825-5536 | F: (847) 825-1456 | www.stle.org | information@stle.org
Follow us on:
October 2022 25
MATERIALS
MATTER
LANE WINKELMANN
VICE PRESIDENT OF TECHNOLOGY 
REM SURFACE ENGINEERING, INC.
Tackling EV noise reduction
The advent and ever-increasing demand for
the quiet electric vehicle is driving the industry
to reduce transmission error and manufacture
higher quality gears.
E
lectric vehicles and plug-in hybrids are becoming a larger segment
of the vehicles on the road every year, and with government incentives to purchasers and manufacturers, this trend will not be reversing. Multiple states are mandating zero-emission vehicles for all new
vehicle sales by 2035.
Manufacturers are embracing the transition and focusing new
vehicle development toward this trend. This was evident during the
most recent meeting of the Gear and Power Transmission Research
Lab (GEARLAB) Consortium Meeting at Ohio State University. The
Consortium currently has 75 corporate members that monitor the
research programs and offer direction for new programs. The overarching theme from the sponsor feedback portion of the meeting was
noise reduction associated with electric vehicle drivetrains.
Figure 1: Predominant cabin noise produced by the gearing mesh vibrations in the
Electric vehicles usually require reduction gears, and even mulS-76 C+ main transmission.
tispeed geared transmissions, to achieve the
appropriate road speeds. The lack of internal
combustion engine noise elevates drivetrain
noise to one of the most notable contributors
to overall noise inside the cabin. Drivetrain
noise can have many contributors, but the
main two are usually transmission error and
frictional vibration from the transmission
itself. Transmission error is the first target of
designers, as it’s the source most commonly
addressed in the industry. Macro geometry
changes can result in a very durable gear that
is still easy to manufacture, but ultimately,
micro geometry changes will be required
to meet the lower noise requirements in an
electric vehicle.
Figure 2: Schematic of an S-76C+ drivetrain
Ultimately, the next largest contributor
highlighting the isotropically superfinished gears.
will become the target as the transmission
error is further minimized. This is typically
We had a chance in 2002 to put this theory into practice with
vibro-acoustic noise associated with the friction generated by the
real-world testing during the qualification of isotropically superfinintermeshing gear teeth that is transmitted through the shafts and
ished gears in the Sikorsky S-76 C+ main transmission. Just like an
amplified by the housing. There are a few methods to address this, but
electric vehicle, the noise level in the cabin is directly correlated
the most common are lubrication and reduction of surface roughness
to the comfort and satisfaction of the occupants. This aircraft had
of the tooth flanks. The first time I heard of vibro-acoustic noise was
the cabin acoustic levels very well documented since it was targeted
around 2001 when Dr. Don Houser of Ohio State University asked REM
toward VIP transport. Figure 1 shows the predominant cabin noise
to participate in a research effort to monitor the frictional noise variations between ground and superfinished gears, as well as the influence
was produced by the gear meshing vibrations of the first few harmonics of the bull gear. The highest noise level was predominantly the
of lubricant viscosity. Both spur gears and helical gears were tested
result of vibrations occurring at the first harmonic of the bull gear
with monitoring inside the gearbox. These early results indicated that
meshing frequency of 778 Hz.
both lubrication viscosity, and surface roughness played key roles in
The gears monitored during this qualification testing were the
reducing the frictional noise (Donald R. Houser, 2001).
26 gearsolutions.com
Figure 3: Measured ATP vibration levels for S-76 C+ main transmission, baseline
versus superfinished.
second stage bevel pinions and gears, third-stage spur pinion, and
third stage bull gear. See Figure 2 for the schematic of the targeted gears. The historically ground gears had a surface roughness
requirement of Ra ≤ 25 µin (0.6 µm). After isotropic superfinishing,
the surface roughness was reduced to Ra ≤ 4 µin (0.1 µm). The main
transmission was assembled with accelerometers in various locations
to best measure the amount of vibration generated by the isotropically superfinished gears, then run through the Acceptance Test
Procedure (ATP), and ultimately a 200-hour endurance test.
The first surprising result was that the vibration levels of the
third stage bull gear 1X mesh (776 Hz) and the second stage bevel
pinion 1X mesh were significantly reduced. When compared to the
baseline data, this indicates a 7-decibel reduction at the third stage
bull gear 1X mesh and a 3.7 decibel reduction at the second stage
bevel pinion and gear 1x mesh. As mentioned earlier, these are the
two frequencies that cause the most aural discomfort in the cabin.
These are also the most difficult to abate due to their vibro-acoustic
nature, which creates noise inside the cabin.
Figure 3 is the measured vibration levels for the S-76C+ main
transmission during the ATP, baseline versus isotropically superfinished gears. (B. Hansen, 2002)
As the old saying says, everything old is new again. Isotropic superfinishing has been used to increase durability and reduce noise in
the aerospace industry for many years. The automotive industry has
not needed to significantly reduce noise in the cabin until now. The
advent and ever-increasing demand for the quiet electric vehicle is
driving the industry to reduce transmission error and manufacture
higher quality gears.
Ultimately, this effort will result in the next failure point becoming the primary nuisance, vibro-acoustic noise.
When we reach this point, isotropic superfinishing may be a tool
to consider.
ABOUT THE AUTHOR
Lane Winkelmann joined REM Surface Engineering, Inc. in 1996. He has held multiple positions there, including director of services where he
managed three ISF® Service Centers covering the U.S. and European markets. He is currently vice president of technology. During his career,
Winkelmann has developed numerous products and processes as well as has co-authored several patents and papers on the use of superfinishing.
He received a B.S. from Texas A&M University in 1991, and his M.B.A. at Tulane University in 2005. He can be contacted at lwinkelmann@
remchem.com.
October 2022 27
TOOTH
TIPS
BRIAN DENGEL
GENER AL MANAGER  KHK-USA
Are my gears properly centered?
Understanding why the center distance between
two gears is important.
A
s we settle into the autumn weather, the changing of the seasons brings a sense of calm. The leaves change color, pumpkin
spice is found in everything, and the cool crisp air brings a sense of
peace after the hazy, hot, and humid days of summer. This peace is
described by some as a sense of Zen. Some see it as a realignment of
their chakras. Others say that they feel more centered at this time
of year. Like people, gears also need to find their center, in order to
mesh properly.
The center distance between two gears operating on parallel axes
is the simplest value to determine. (Figure 1) The center distance of
these gears is:
Figure 1.
Mounting Distance
where
a = the center distance
d1 = the pitch diameter of the pinion
d2 = the pitch diameter of the driven gear
This formula is valid whenever the gears are produced without a
profile shift. If a profile shift is introduced, the values of d1 and d2
must reflect the working pitch diameter instead of the normal pitch
diameter for the equation to be correct.
The center distance calculation will result in a nominal value
for which a tolerance will need to be applied. It is always recommended to have the tolerance range for the center distance to be
at the nominal value on the lower limit and a positive range on the
upper limit. When the center distance is set to a value less than the
nominal value, then the gears will not perform as desired. Setting
the gears at the nominal center distance allows for the teeth of each
gear to engage at the proper location on the gear tooth as well as
minimizes noise and permits the transfer of lubricant into the mesh.
If the center distance is too large, then the gears will not transfer the
torque as designed and will be very noisy.
For gears that have intersecting axes, such as bevel gears, the
center distance is known as the mounting distance. The mounting
distance is measured from the back of the hub of a bevel gear to the
point of intersection of the pitch diameters (Figure 2). This value
is typically set by the manufacturer as it is not defined by the gear
geometry itself.
The tooth of a bevel gear is defined as having a toe and a heel. The
heel is the backmost portion of the tooth and the tip of the tooth at
the heel is the point at which the gear’s outer diameter is measured
(Figure 3). This is a known point and can be used to set the mounting distance value.
As with parallel axes gears, it is recommended to set bevel gears at
the nominal mounting distance or slightly larger. Forcing the gears
into the mesh will cause premature wear as there will be a buildup of
heat due to the excess friction and the lack of lubricant in the mesh.
For gears with non-intersecting and non-parallel axes, such as
28 gearsolutions.com
Figure 2.
Heel
Toe
Bevel Gear
Figure 3.
Worm
Center distance
Worm Wheel
Figure 4.
Figure 5.
worm gear pairs, the center distance is also measured as one half of
the sum of the pitch diameters (Figure 4).
Worm gear pairs operate best when the center distance is set to
the nominal value on the lower limit and a positive value on the
upper limit.
Unique to all the center distance calculations is that of a gear
rack meshing with a profile shifted pinion (Figure 5). The formula
for this value is:
z = the number of teeth on the pinion
m = the module (pitch of the gear)
H = the height of the rack from the base to the pitch line
x = the coefficient of profile shift
If the pinion is not profile shifted, then the center distance for
the rack and pinion is equal to one half of the pinion pitch diameter
plus the height of the rack from the base to the pitch line.
For each of these gear styles, it is important to know what the
nominal center distance value is and apply a suitable tolerance. Doing
so will allow for a proper mesh, an acceptable amount of backlash,
and the opportunity for lubricant to flow through the teeth. This
will keep both you and your gears centered.
where
a = the center distance
ABOUT THE AUTHOR
Brian Dengel is general manager of KHK-USA, which is based in Mineola, New York. Go online to www.khkgears.us
October 2022 29
HOT
SEAT
D. SCOTT MACKENZIE, PH.D., FASM
SENIOR RESEARCH SCIENTIST–METALLURGY 
QUAKER HOUGHTON INC.
Nitriding of steels
Adaptable process yields surface hardness
without the risk of distortion that accompanies
higher-temperature treatments.
I
n this column, we will discuss the nitriding of steels.
Nitriding introduces nitrogen into the surface of a steel at a lower
temperature than carburizing. Temperatures of 500-550°C are often
used. Since nitriding does not involve heating into the austenite region
and subsequent quenching, nitrided parts offer minimum distortion
and good dimensional control. In most commercial applications the
surface layer is up to 200-300 µm thick and rarely exceeds 600 µm.
Nitrogen forms a solid solution with ferrite at nitrogen contents
up to 6 percent. At a nitrogen concentration greater than 6 percent,
γ’ (gamma prime) with a composition of
Fe4N, is formed. At nitrogen contents greater
than 8 percent, the equilibrium product ε is
formed, with the composition of Fe3N.
In general, nitrided surface layers are
stratified into layers, with the outer surface
as γ’, and the inner layer as ε. The outer layer
of γ’ is often referred to as the “white-layer.”
This surface layer is undesirable as it is hard,
but very brittle. Typical microstructure of a
nitrided part is shown in Figure 1.
For gas nitriding, the primary reaction
is the decomposition of ammonia to form
elemental nitrogen which diffuses into the
steel:
The depth of case and case properties are
dependent on the amount of nitride-forming
alloys that do not exhibit a sharp transition between the base material and the diffusion zone, the total case depth is defined as the
depth below the surface where the hardness is 10 percent higher
than the core hardness. The effective case depth is defined as the
case depth where the hardness exceeds a certain value. This value is
defined by specification or drawing.
PROCESSES
GAS NITRIDING
Gas nitriding uses anhydrous ammonia in either a single-stage or
two-stage process [2]. In the single-stage process, parts are processed
at 495-525°C (925-975°F) for a desired time. This process produces a
brittle white compound nitride layer at the surface. The Floe process,
which is a two-stage process, reduces the amount of brittle white
Figure 1: Typical nitrided microstructures found. Nitrided SAE 41B50 alloy quenched and tempered to 325 HV.
elements in the steel. As the alloying content
The surface was electro-less nickel plated prior to mounting for edge retention. The left view reveals the depth
is increased, so is the hardness of the case.
of the nitrided case. The right view shows evidence of intergranular nitrides. Tint etched with Beraha’s CdS
However, the additions of alloying elements
reagent. (Courtesy: George Vander Voort).
also slow down diffusion of nitrogen, thus
layer present. The first stage is performed similarly to the singleincreasing process time. Figure 2 shows typical process times to
stage nitriding, while the second stage is performed at a higher temachieve a specific case depth for typical nitriding materials.
perature of 550-565°C (1,025-1,050°F). This second stage acts in an
Nitriding steels are medium carbon steels that contain strong
identical fashion as the diffuse stage in boost-diffuse carburizing.
nitride-forming elements such as aluminum, chromium, or molybdenum. The highest hardening is achieved with 1 percent aluminum.
This second stage decreases surface hardness, reduces the thickness
These steels are usually quenched and tempered prior to nitriding.
of the white layer, and increases the case depth of nitriding.
Nitriding is accomplished by gas, salt, or ion nitriding. Process
MOLTEN SALT NITRIDING
times for gas nitriding can be rather long, depending on the depth
Molten salt bath nitriding is still done, but at a reduced level due
of effective case desired. Ion nitriding has faster nitriding times,
to environmental and regulatory concerns. In this process, at temdue to the saturation of the surface with nitrogen resulting in faster
peratures like gas nitriding, a molten bath of nitrogen containing
diffusion.
salt containing cyanide or cyanates is used. Critical dimensions can
The total case depth is often defined as the dark-etching zone on
be held because of the uniform heat transfer of molten salt, and
the component cross-section, determined metallographically. For
30 gearsolutions.com
Process
Temperature
Case Depth
Case Hardness (HRC)
Process Characteristics
Gas
480-590°C
125μm - 0.75 mm
50-70
Hardest cases from nitriding steels, quenching not required, low
distortion, process is slow, is usually a batch process.
Salt
510-565°C
2.5μm - 0.75 mm
50-70
Usually used for thin hard cases, no white layer. Most are
proprietary processes.
Ion
340-565°C
75μm - 0.75 mm
50-70
Faster than gas nitriding, no white layer, high equipment costs,
close case control.
Table 1: Comparison of different nitriding processes [2].
because of the low temperatures used. Molten salt nitriding is also
quicker due to the higher nitrogen potential of the bath, compared
to gas nitriding.
PLASMA (ION) NITRIDING
In plasma (ion) nitriding, parts are processed in a vacuum. The parts
are electrically charged with a high voltage, and nitrogen is introduced into the chamber. A plasma is formed due to voltage potential. This voltage potential causes the individual nitrogen atoms to
accelerate and impact the part. This process heats up the part, cleans
the surface, and nitrogen is absorbed into the part. It is possible to
selectively mask parts for nitriding through control of the plasma.
In gas or salt nitriding, various stop-off or other chemicals are used.
A beneficial compression residual stress field at the surface of the
part increases fatigue resistance. This process reduces even further
the distortion that can occur in gas nitriding, and provides excellent
control of case depth, chemistry, and uniformity.
REFERENCES
[1] A. K. Rakhit, “Nitriding of Gears,” in Heat Treatment of Gears: A Practical
Guide for Engineers, Materials Park, OH, ASM International, pp. 133-158.
[2] J. R. Davis, “Process Selection Guide,” in Surface Hardening of Steels,
Materials Park, OH, ASM International, 2002, pp. 1-16.
[3] D. K. Dwivedi, Surface Engineering — Enhancing Life of Tribological
Figure 2: Nominal times for different nitrided depths [1] during gas nitriding.
ABOUT THE AUTHOR
Components, New Delhi, India: Springer (India) Pvt. Ltd., 2018.
D. Scott MacKenzie, Ph.D., FASM, is senior research scientist-metallurgy at Quaker Houghton. He is the past president
of IFHTSE, and a member of the executive council of IFHTSE. For more information, go to www.houghtonintl.com.
October 2022 31
ISSUE
CHAMFERING & DEBURRING / POWDER METAL GEARS
FOCUS
COULD SWITCHING
FROM MACHINING
TO GRINDING
IMPROVE THE MANUFACTURING
PROCESS?
32 gearsolutions.com
Many high-performance industries including those
in aerospace and automotive sectors have made
tremendous investments in next generation grinding
cells in order to capture the capabilities of grinding
and machining for optimizing processes.
By ANDREW BIRO
W
hile recent advancements
in machining centers have
allowed for increased capability around high-volume
operations, there are several factors
that still necessitate the need for grinding. Grinding has many benefits over
conventional machining, including longer tool life, finer surface finishes, and
the ability to more effectively remove
difficult-to-machine materials (such as
new ceramics composites and carbideimpregnated metal alloys). This article
highlights the benefits new grinding
technology provides over conventional
machining, and provides insight into
considerations for converting current
machining applications to grinding.
GRINDING VS. MACHINING
Machining
Grinding
Traditionally, machining is a very efficient process capable of removing material quickly. Driven by (relatively) large
cutting surfaces and large chip sizes, the
amount of frictional interactions (rubbing and plowing) between the tool and
the workpiece when compared to grinding is minimal; this reduces the need for
complex coolant systems. However, the
large chip size can have a detrimental
impact on the final surface roughness of
the part, often requiring a subsequent
Figure 1. (Courtesy: Norton | Saint-Gobain)
grinding process to generate fine finishes. Recent advancements in abrasive grain and bond
In addition, the large increase in number of cutting
chemistries, and machine and coolant nozzle technolopoints allows for a more distributed, uniform wear
gies have allowed grinding applications to compete and
along the grinding wheel, leading to longer wheel life
even exceed machining material removal rates on new
and fewer tool changes. A typical grinding wheel uses
and difficult-to-machine alloys. This, coupled with the
hard ceramic or super-abrasive grains, which are significantly harder than many of the machining tools
added benefit of being able to rough and finish grind on
on the market (although ceramic tools come close).
the same machine platform, has become a cost-effective
means of manufacturing. (Figure 1)
CONSIDERATIONS FOR CONVERTING
The benefits of grinding stem from having hunA MACHINING PROCESS TO GRINDING
dreds of cutting points on a typical grinding wheel
When considering whether an existing machining
(vs. a few on a typical mill or lathe). The many cutting points will tend to create smaller chips, thereby
or turning application can instead be performed by
improving the surface finish and imparting a comgrinding, the first step in the process should be to evalpressive residual stress on the surface of the part.
uate the process limitations, pain points, and materiOctober 2022 33
als. Common issues that can lend themselves
to a grinding solution include:
What materials am I trying to machine?
Difficult to machine materials are now being
pushed to higher volumes, often driven by
advantages in performance over conventional materials. These include ceramic composites, carbon fibers, heavily alloyed aerospace
metals, and some powder metals. They are
notoriously difficult to machine due to their
high hardness and chipping potential. This
is where grinding, where smaller chips are
generated and the surfaces are left in a state
of compressive residual stress, can be an economic solution.
Does the application require both high
stock removal and a very precise form and
finish?
Through changes in wheels and/or dressing,
the characteristics of the grinding action
can be modified to either target a high-stock
removal or generate a fine finish. The advantage with grinding is this can often be done
using the same grinding wheel, or at least
the same machine system.
Do I currently have a manufacturing line
where a grinding operation is preceded by
a machining operation? Could I move the
process to a single grinder to save floor
space and tact time?
Superabrasive electroplated tools can offer cycle time benefits when grinding. (Courtesy: Norton | Saint-
Gobain)
Saving floor space is critical in high-production manufacturing, and truncating a process to fewer machines can have a large impact on the efficiency
of the process. This also reduces the need to move parts from one
machine to another, which can drive down overall process time.
Is tool life or tool changeover time on my machining operation
affecting production rates?
The need to stop an operation to replace and re-sharpen the cutting tools can lead to higher cost per part and frequent stoppages.
Using a grinding wheel can help minimize the down time and resharpening costs of machining operations. This is particularly true
for new, difficult-to-grind alloys.
Are burrs an issue?
Larger burrs come from larger chips. Using a grinding wheel can
often help lower the tendency for large chips and therefore minimize
the need for deburring processes.
Are residual stresses in the part surface affecting form or
function or rework?
One significant benefit to grinding is the compressive residual stresses imparted into the surface of the part during a machining process.
If residual stresses are causing parts to twist, warp, or bend after your
machining process, grinding is an excellent way to remove material
and relieve some of these stresses in the part.
PRODUCT CONSIDERATIONS
For new processes, selecting a grinding platform has several advan34 gearsolutions.com
Grinding has many benefits over
conventional machining, including
longer tool life, finer surface finishes,
and the ability to more effectively
remove difficult-to-machine
materials.
tages over conventional machining platforms, including higher stiffness, dressing capabilities, and precision coolant systems. However,
if looking to retrofit an existing process that uses machining equipment, it can often be achieved with some coolant modifications and
electroplated grinding wheels, which require no dressing in order
to maintain their form.
The retrofitting required in these situations is primarily related
to converting the coolant system to grinding oil, which is typically
optimized for a variety of conditions such as higher flash points, low
foaming, and environmental/cleanup factors. The biggest change
in retrofitting an existing process is to ensure adequate velocity to
match the wheel speed. Compared to purchasing new equipment,
these are relatively cost-effective measures for converting existing
machining processes to grinding.
The benefits to electroplated plated wheels in these applications
include the ability to plate nearly any shape, including drills, milling cutters, wheels, quills, etc, and the ability to hold fine tolerances
(down to 0.0004” in some cases) where critical features need to be
generated.
EXAMPLES
There are many examples of how customers have adapted this
machine-to-grind concept for overall process improvements and cost
savings. In one example, an energy company was ceramic turning
dual bearing races for a turbine. The challenge was to ensure the
races were identical to each other after being hardened to a 65RHC.
Due to the wear on the ceramic inserts during turning, there was a
significant amount of part rework to get the races to match. The solution was to implement an electroplated grinding wheel that could
grind both hardened races simultaneously. Because the grinding
wheel used cBN abrasives and had very low and uniform wear, this
eliminated the rework. As a result, this brought the overall cycle time
per part from 30 minutes to 11 minutes, saving the company more
than $80,000 annually.
Another example is grinding gears from solid. It is common practice to mill or hob gears in a softened state, then harden, and grind
the final finish. Some customers have adopted the approach of hardening the gears first, then rough and finish grinding on a single
grinder with high-performance grinding wheels such as Norton
Xtrimium or Quantum. In one example, a customer was able to cut
cycle time in half by applying this technique, thereby lowering its
ABOUT THE AUTHOR
overall manufacturing costs.
Not all customers will be able to modify or purchase new equipment to test whether grinding is a good solution vs. machining. In
one case, a customer was using a machining process on a simple
3-axis machining center. They were having challenges with material
tearing when running small ball mills on tight tolerance features.
The approach they took was to order electroplated quills of the same
size and shape as the ball mills to use for the finishing operations.
This eliminated the material tearing (due to the smaller chip size)
and required no change in the existing equipment to implement.
Although the grinding tools have a higher price than the ball mill
tools, this was justified by the significant cost savings in rework time
by not having the tear outs in the material.
Many high-performance industries including those in aerospace
and automotive sectors have made tremendous investments in next
generation grinding cells in order to capture the capabilities of grinding and machining for optimizing processes. For those customers
with low-mix, high-volume production, using the latest in high-performance grinding machine platforms and wheel technology can
show significant improvements relative to machining. But for many
smaller companies, these cells might not cost justify, especially for
high-mix, low-volume facilities.
In these cases, converting an existing machining process to grinding with electroplated tools can have profound benefits in terms
of cycle time, lower overall cost per part, improved tool life, and
consistency in part quality.
Andrew Biro is an applications engineer with Norton | Saint-Gobain (www.nortonabrasives.com).
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October 2022 35
ADDRESSING TRADITIONAL
PROBLEMS AND
CHALLENGES
WITH AM
SOFTWARE
36 gearsolutions.com
Wayland Additive has taken a pragmatic view of the
development of software associated with its Calibur3
metal additive manufacturing system.
By DAVID KNIGHT
W
hen focused on AM software per se, from
the outset it is important to understand
that it can mean different things to different organizations and/or individuals. If
you consider the full breadth of the 3D CAD to PRINT
workflow, the range of software required for key disciplines is extensive. To offer some idea — in generic
terms — this can include: design, simulation, part
optimization, design repair/fix, build optimization
(nesting/part orientation etc.), support generation,
build file generation (including melting parameters/
height above powder/preview toolpath/estimated
build time), slicing, machine control, build control,
calibration and maintenance, and real-time monitoring and analysis.
The first four categories on the list are very broad
terms for a wide range of software dedicated to preparing part data for the machine. The rest of the list
covers the software involved in managing that data
in relation to the machine and its operation. For the
purposes of this article, we are dealing with the latter.
It’s not overstating things to say that all forms of
AM software remain a potential barrier to entry for
many potential users of AM and often present headaches for current users. This is not helped by the many
vested interests in this area, which rarely pull in same
direction and, as such, lose sight of the actual requirements of end-users and the need to support their AM
endeavors.
THE WAYLAND APPROACH
Wayland Additive has developed the Calibur3 metal
Additive Manufacturing (AM ) system featuring the
NeuBeam® process. NeuBeam® offers a new — and
more open — approach to electron beam (eBeam)
powder bed fusion (PBF ) metal AM technology that
represents a big step forward compared with existing commercial PBF systems. The technology overcomes the compromises that most companies have
to contend with when using either laser or eBeam
PBF metal AM . Neubeam® effectively neutralizes
the charge accumulation generated by an electron
beam, which offers greater flexibility than laser PBF
while overcoming the traditional stability issues of
eBeam PBF. The development of Calibur3 has also
seen Wayland place a heavy emphasis on specific
software development to support the machine and
further enable users.
Wayland is not entering the fray on AM software
at the front (or design) end of the workflow. However,
aware of the many limitations of AM machine soft-
All forms of AM software remain a potential barrier to entry for
many potential users. (Courtesy: Wayland Additive)
ware, Wayland Additive has — from the outset —
embedded an “open” approach to its system software.
To be clear, this is not an “open source” offering but
rather an “open access” approach that provides adopters with distinctly more access to the printer than any
comparable system on the market, together with a
streamlined and intuitive interface.
Many users lament that AM systems are effectively black boxes — with inflexible parameters whereby
an STL file is essentially fed in at one end and a part
comes out at the other — and there is no way of controlling the process. Wayland’s open access approach is
designed to allow users to directly manage key parameter settings, allowing them to alter build parameters
to suit their needs, and this is particularly attractive
for R&D applications and material development.
Wayland’s software is designed to erode the image
of metal AM systems being difficult to use, which is
a current market perception. Moreover, in terms of
the frontend of the workflow, the company is agnostic
and does not force users to adopt any specific (and
potentially costly) software. Calibur3 allows for the
use of any software tools of a customer’s choosing, the
process chain only kicks in when it becomes process
specific.
There are three key elements to Calibur3 software:
PREP, BUILD, and VIEW.
PREP
Wayland’s PREP software (as the name implies) focuses
October 2022 37
Wayland’s PREP software focuses on the preparation stage of the build and includes slicer and build-file generation. (Courtesy: Wayland Additive)
on the preparation stage of the build and includes slicer and build-file
generation. The input is sliced parts in CLI or 3MF format, and the
output is the Wayland Build file (.WAB). PREP also allows the user to
assign melting parameters, calculate height above powder, preview
the toolpath, and estimate build time.
Wayland has built a workflow that offers two pathways, a dedicated and fast path for production, which works for users looking
to use the technology to manufacture parts from the outset, as well
as options for R&D — specifically for new material and application
development. For the latter, three key sets of parameters are opened
up, which essentially provides unlimited options for users. These
three parameters include:
 Geometry (offsets/overhangs, etc).
 Scanning of part — in what order are all points addressed (infinite).
 Energy deposition — how much energy/dwelling on a certain
point.
With this open-access software approach, Calibur3 users can
alter the beam current and focus. Neither of these parameters can
be changed quickly, but they can be altered depending upon specific
material used and the vagaries of a particular application. One thing
that can be changed quickly is dwell time — i.e. how long does the
beam linger on a certain point and how much energy is focused on
a certain point, and this can be altered via closed-loop feedback in
real time.
There are numerous unique aspects to the NeuBeam® process,
something termed the software-led “melt strategy” being key as it
has a significant impact on outcomes, and the type and validity of
parts that can be produced on Calibur3.
The proprietary melt pool strategy uses the power and speed
38 gearsolutions.com
of an eBeam more efficiently; eBeams are characterized by their
high power and high scanning speed, and Wayland has worked on
how to best use this power and speed. Calibur3 splits each layer
of a part under construction into small zones and assigns a melt
pool to each zone. The melting strategy is, at the same time, energy
efficient, and by melting different zones in parallel, it allows higher
productivity rates regardless of geometry. The power and beam
speeds required using traditional melting strategies are incredibly
geometry dependent.
A common approach has been to dynamically change the energy
based on key features of the geometry (area of part, overhangs, line
lengths, end-of-line turning points) to maintain accurate geometry and material quality. People using alternative eBeam technologies will be all too familiar with phrases such as “turning point
function,” “thickness function,” ‘speed function,” and “current
compensation function,” all of which are tuned by lengthy experimentation. This makes the process complicated and non-intuitive
for the user, and it is extremely difficult to diagnose the precise
cause of problems when they don’t work for particular geometries.
This is not only time- and labor-intensive, but can be very costly.
At Wayland, the new melting strategy addresses these issues, and
everything can be previewed and verified in PREP before being
loaded onto the machine.
BUILD
Wayland’s “BUILD” software module includes:
 Machine control (with interfaces to all sub-systems [high-voltage, beam control, motion, PFS, chiller, electronics, cameras, etc.] all
via a touch screen human-machine interface [HMI]).
 Build control (load build files and run build scripts).
Users of the BUILD software module can access melt parameters within certain guidelines, which protect the user and the machine from injury or damage. (Courtesy:
Wayland Additive)
 Calibration and maintenance.
 Real time logging and analysis (with direct output to Wayland’s
View software). An embedded JavaScript engine for running build,
calibration, and maintenance scripts.
The stand-out features that Wayland has built into the software
are genuinely unique within this segment of the metal AM market
and, again, revolve around user accessibility. Users can access melt
parameters within certain guidelines, which protect the user and the
machine from injury or damage, and there are four levels of access
that grant the user the ability to control parameters to a greater or
lesser extent.
The hardware and software are designed with the user in mind
and focused on functionality and productivity.
VIEW
Wayland’s VIEW software is effectively a consolidated “view” of
the build that has just taken place. VIEW offers users a completely
offline tool that can run on a separate workstation or on the cloud.
It has been developed to access and use the data generated by the
in-process monitoring (IPM) capabilities of Calibur3. At the end of
a build, the data generated by the different IPM capabilities can be
downloaded, analyzed, and archived. This provides a plethora of
opportunities to analyze meltpool and powder spreading strategies, optimize process parameters and develop machine learning
algorithms. In addition, if a build fails the causes of the failure can
be identified, understood, and avoided in the future.
VIEW is open access and customizable to user requirements,
in the sense that the user can decide what can be seen and everything is synchronized creating a digital dashboard. VIEW can be
integrated with users preferred tools, meaning once again that it
is software agnostic.
SUMMARY
Wayland Additive has taken a pragmatic view of the development of
the software that is associated with its Calibur3 metal AM system.
Learning from the frustrations that users of metal AM processes voice
— most importantly in respect of the access that users can have to
alter key build parameters — the open access approach stimulates the
ability of users to adapt the technology to the specifics of particular
materials and particular applications. Wayland supports material
development with this integrated approach, including for materials
that are difficult to process using AM. The company’s whole software
suite is very powerful in this regard.
Wayland’s software development is based on the fact that everything should be in one place, synchronized, and accessible quickly.
Accessible menus are designed to be two or three steps deep to avoid
endless drilling down to get to what is needed, and the HMI is intuitive and simple to use.
ABOUT THE AUTHOR
David Knight is software lead at Wayland Additive. NeuBeam technology has been developed in-house from the ground up by a team of physicists
that have worked for many decades with electron beam technology and industrial systems in the semi-conductor industry. The science, combined
with extensive expertise and experience has allowed Wayland Additive to develop a very capable and reliable system rather than imitating existing
systems or adapting off-the-shelf components and re-purposing them.
October 2022 39
STREAM
FINISHING
THE GREEN ALTERNATIVE
TO CHEMICALLY
ACCELERATED PROCESSES
40 gearsolutions.com
Stream finishing is suitable for a variety of
components, including those with complex
geometries, a weight of up to 200 kilograms and a
diameter of up to 650 mm, such as turbine discs,
turbine blades, blisks, servo valves, and gear wheels
for the aerospace industry.
By JASON CHIN
T
here are numerous methods and processes available for post processing industrially manufactured metal components, with various advantages and drawbacks depending on the size,
geometry, material and finishing requirements. We
look at four well-established processes on the market
for finishing gear wheels and assess them in terms
of health and safety, environmental impact, and costeffectiveness.
ONE GEAR WHEEL: MANY
PROCESSING CHALLENGES
Many highly loaded steel gear wheels are produced for
use in the aerospace industry that must be ground to
an extremely high degree of precision and hardened to
levels greater than 60 HRC. The surface of a gear wheel
is solid and tough. If it is to function safely and reliably later on, the surface structure must be flawless
and extremely isotropic, meaning it must be highly
uniform in all directions. As well as requiring a roughness of below Ra 0.1 µm, the involute surface must not
be wavy or show any grinding grooves. In addition,
the edges on the sides and on the tooth head must be
evenly rounded. (Figure 1)
NOT ALL PROCESSING
METHODS HIT THE MARK
Now that we know the criteria, we need to identify
which process comes out on top where it really matters. One option is manual or mechanical robotic
smoothing and rounding. Here the processing quality
throughout the tool’s life cycle does not remain constant, as progressive wear on the grinding wheel or
brush results in an ever-more imprecise surface finish
over time. Both methods produce very uneven results
when processing inner geometries because the tools
can accommodate different components only to a very
limited extent and are difficult, if not impossible, to
position in tight places. Components with very narrow
tolerances lay bare the limitations of these methods,
which cannot process them effectively. Current technology often favors trough vibrators for processing. Using
certain acidic process liquids can help to reduce process times. The types of liquids used include mixtures
containing phosphate salts, phosphoric acid, oxalic
Figure 1
acid, sodium oxalate, sulphate, sodium bicarbonate,
chromate, sodium chromate, chromic acid, and sulphuric acid. Most of these substances are hazardous and
employees require special protective equipment when
handling them. (Sodium) chromate and chromic acid
have been classed as substances of very high concern
by the REACH regulation (Registration, Evaluation,
Authorization, and Restriction of Chemicals) as they
are carcinogenic, mutagenic, and in the case of sodium
chromate, toxic to reproduction. Along with sulphuric
acid, oxalic acid, and phosphoric acid, they are also skin
sensitizing and, in some cases, toxic. For this reason,
the Globally Harmonized System of Classification and
Labelling of Chemicals (GHS) has listed the following
properties for most of these substances:
 Acute toxicity.
 Hazardous to aquatic environment.
 Various other health hazards.
 Skin irritant that is corrosive to metal and may
cause serious eye damage.
While this process might tick all the boxes in terms
of finishing requirements, the process liquid can generally only be used once and must be replaced once processing is finished. This results in increased purchasing,
neutralization, and disposal costs, meaning the process
is far from cost effective. As we have already seen, the
use of these hazardous substances also brings with it
health and safety and environmental risks.
Dry electropolishing processes are another option
available on the market for polishing metal workpieces
in a single operation. They use electrolyte granulate to
October 2022 41
Figure 2
reach and process even inner geometries. However, not all granulate is
suited to the workpiece shape, and electrolyte can get jammed in the
workpiece. One of the biggest drawbacks is that this electropolishing
method cannot remove the waviness caused by the forming process
of grinding as its abrasion level is simply too low. The average process
time ranges from 30 minutes to several hours. What is more, by nature
of the process, only the exposed areas can be properly finished. The
electrolyte granulate must also be disposed of as hazardous waste once
it has reached the end of its given service life, and buying new granulate to replace it is an additional financial burden. (Figure 2)
STREAM FINISHING: A GREEN ALTERNATIVE
One thing is clear: Stream finishing results are on a par with those of
chemically accelerated mass finishing. But the key difference is that
stream finishing is a purely mechanical process that does not use
acids or electrolyte granulate, making post-processing much more
cost effective.
HOW DOES STREAM FINISHING ACHIEVE
SUCH GOOD RESULTS?
In stream finishing, which was developed in-house by OTEC, the components are clamped in a holder and immersed in a rotating container filled with an abrasive or polishing medium. The workpiece
itself also rotates, and the relative motion between the component
and the media produces an even finish without the need for manual
work. The process turns out highly precise surfaces with a roughness
as low as Ra 0.01 µm on complex geometries.
The enormous machining forces used in stream finishing can
remove material faster and more accurately than any other type of
surface processing. The fine media used can get through to the inner
geometries and process them without difficulty.
GETTING INTO GEAR: WEAR-RESISTANT
GEAR WHEELS COURTESY OF STREAM FINISHING
Lubricating film can help to reduce wear and friction between gear
wheels. During stream finishing, microscopic lubrication valleys are
produced on the workpiece surface. These are very beneficial as they
can retain lubricant. If the surface is too smooth and flat, the lubricating film between the interlocking teeth can break, resulting in
42 gearsolutions.com
Figure 3
the seizure and complete failure of the gearbox.
Stream finishing improves the overall surface quality of the gear
wheels by leveling the surface and removing roughness peaks and
machining grooves to produce an isotropic surface and an agreed
roughness based on the customer’s requirements. It employs highfriction energy to prepare the gear wheels for use when they are later
run. In addition to reducing friction and wear, the process also produces a shear layer by changing the surface structure and creating
compressive residual stress, which is highly effective in conditioning
the gear wheel for use.
STREAM FINISHING REDUCES REJECT RATE
The stream finishing process boasts an extremely low process variation of just 1 µm — which is five to 10 times lower than chemically
accelerated processes. (Figure 3)
This is good news for the production process as it means there is
greater leeway to use the tolerance range in the upstream forming
process of grinding. Having to reject workpieces due to high variation
during the finishing process is now a thing of the past. When gear
wheels must be ground to an extremely high degree of precision,
reducing the reject rate can save tens of thousands per reject.
APPLICATION EXAMPLE FOR A HIGHLY LOADED GEAR WHEEL
Before processing:
Ra 0.19 µm
Rz 1.358 µm
Rpk 0.418 µm
After processing:
Ra 0.042 µm
Rz 0.551 µm
Rpk 0.139 µm
INITIAL CONDITION
 Gear wheel made of hardened steel, 60-plus HRC, ground to an
extremely high degree of precision.
 Initial roughness: Ra of 0.19 to 0.21 µm.
 Process time: 20-35 minutes.
PROCESSING RESULT
 Extremely isotropic surface.
 Final roughness: Ra 0.042-0.084 µm.
 Striations and grooves removed.
 Uniform edge rounding.
 Very low process variation.
 Microscopic lubrication valleys produced on the surface.
THE BENEFITS OF STREAM FINISHING
 Rapid and efficient deburring, edge rounding, and smoothing
in one single step.
 Very low process variation (1 µm) compared with other methods
(~5-10 µm).
 Exceptionally high-process reliability obtained by mixing new
and reused grinding bodies.
 Extremely isotropic surface.
 No roughness peaks (Rpk < 0.1 μm): less wear, no run-in necessary, longer oil service life.
 Low risk of micropitting.
 Cost-effective process suitable for recirculation.
 No expensive disposal of abrasives.
 No handling of dangerous chemicals.
 Very short processing times — four times quicker than chemically accelerated processes.
Stream finishing is suitable for a variety of components, including
those with complex geometries, a weight of up to 200 kilograms and
a diameter of up to 650 mm, such as turbine discs, turbine blades,
blisks, servo valves, and gear wheels for the aerospace industry.
ABOUT THE AUTHOR
This article was written and arranged by Jason Chin of Otec USA with information presented by the Otec press team in Germany. For more
information, go to www.otec.de/en.
October 2022 43
COMPANY
PROFILE
AFC-HOLCROFT
INNOVATION
THAT
ENDURES
AFC-Holcroft designs and builds many
different types of thermal-processing
equipment. (Courtesy: AFC-Holcroft)
44 gearsolutions.com
AFC-Holcroft produces high-quality,
thermal-processing equipment used in the production
of metal components, while providing related
aftermarket service.
By KENNETH CARTER, Gear Solutions editor
I
n order to give gears the necessary wear properties,
those newly manufactured gears need to be heat
treated. It takes thermal processing equipment to
make that happen.
By offering a variety of custom designed thermal
processing equipment including integral quench
batch furnaces (UBQ and UBQA), continuous pusher
furnaces, rotary reheat furnaces, and more, AFCHolcroft is able to offer gear manufacturers equipment
capable of producing the best products available.
“Right from the start, we review each customer’s specific gear-design requirements,” said Tracy
Dougherty, vice president of sales at AFC-Holcroft. “We
explore all options for the heat-treating process, from
the best type of equipment (continuous or batch), to
the quenchant (i.e. oil, salt, etc.) to minimize distortion and the need for expensive secondary machining
and grinding operations.”
MANY DIFFERENT TYPES OF EQUIPMENT
To that end, AFC-Holcroft designs and builds many different types of thermal-processing equipment including continuous pusher furnaces (single row and multirow) for high volume; as well as integral quench batch
furnaces, which offer maximum flexibility in terms
of volume, footprint, and process, and rotary furnaces
used mostly for reheating and press quenching applications, according to Dougherty.
“As part of these systems, we also provide full
turnkey automation,” he said. “And by automation,
I mean in some cases there are customized multihead quench presses that have automatic load-unload
systems, which may be robots, or they may have custom gantry type systems. This equipment can also
include a variety of quench media: oil, salt, polymer,
and water.”
EQUIPMENT MADE TO ORDER
Customers coming to AFC-Holcroft won’t find much
by way of inflexible, off-the-shelf solutions. Each and
every furnace from AFC-Holcroft is customized to
meet technical specifications and process requirements, according to Dougherty.
“We provide a customized solution regardless of
industry, which includes the gear industry,” he said.
“That has always been a big part of our business —
gears for automobiles, trucks, buses, agricultural
equipment, and construction/mining equipment as
well as a variety of other industries. Our goal is to provide a robust solution that’s customized to the customer-specific needs rather than trying to sell them a
standard piece of equipment and make their product,
process, or production quantities match something
standard. We match the equipment to what they need.
Another focus for us is to provide a solution that maximizes their uptime — ease of maintainability, part
and process tracking (IOT), remote diagnostics (RDX),
while minimizing distortion.”
REDUCING DISTORTION
In its long history, Dougherty pointed out that AFCHolcroft has always searched for methods to reduce
distortion.
“(Reducing distortion) eliminates that need for
secondary operations,” he said. “That’s always been a
push for us: to look at different types of equipment
and quench media to help reduce that distortion.
As the automotive industry moves to EVs, the gears
require much higher RPMs than we’ve seen historically, so distortion becomes more important than ever.
Our company continues to invest in R&D projects to
develop new equipment and processes that are going
to help our customers well into the future. In fact, we
currently have several EV-related projects in various
stages of engineering and manufacturing.”
A GREENER FUTURE
Another aspect of AFC-Holcroft’s approach to the gear
industry and beyond is the company’s push to offer
green technology to reduce its customers’ carbon footprint, according to Dougherty.
“We invest in new product development through
the use of CFD modeling,” he said. “The expansion of
salt quenching as an alternative to oil is an example.
Salt-recovery systems can reclaim more than 98 percent of the salt from the wash tanks and return it to the
quench tank. We’re also developing green technology
alternatives through the use of high-efficiency burners with recuperation, heat-recovery, electric heating,
and hydrogen-heating systems. We’re currently doing
testing and proof-of-concept on hydrogen heating.
These are all efforts designed to help our customers
reduce their carbon footprint.”
By offering state-of-the-art equipment and innovative technology, AFC-Holcroft is poised to deliver
just what a customer may need, but it takes a lot of
October 2022 45
AFC-Holcroft is able to offer gear
manufacturers equipment capable of
producing the best products available.
(Courtesy: AFC-Holcroft)
planning to get there, according to Dougherty.
“We really like to be involved as early in the process as possible,”
he said. “Best case is when we can get involved very early on, when a
customer is just putting proof-of-concept together, and they’ve got a
46 gearsolutions.com
new product that might be five or 10 years down the line. That’s when
we like to be engaged and involved with our customers, because we’re
really a company of engineers who thrive on the ability to help our
customers pick the best solution, and the best way for us to do that
AFC-HOLCROFT’S NO. 1 GOAL:
CUSTOMER SATISFACTION
With a 98-percent customer retention rate, AFC-Holcroft has obviously found the best path to customer satisfaction, according to
Dougherty.
“One of the things that we take pride in as a company is an
extremely high customer retention rate,” he said. “When our customers buy from us, they come back. And the reason they do is that
we’ve got a very strong team of dedicated people who have a high
sense of urgency and pride in servicing our customers after the sale.
For many of our customers, once they purchase the type of equipment that we build, they might have enough capacity to last them
for another decade and beyond, but that doesn’t change the care our
team takes with that particular customer. We are proud of retaining
our customers by taking good care of them with service and support,
even long after the installation.”
LONG HISTORY
Depending on which timeline you follow, AFC-Holcroft has a long and
storied history. Holcroft was started in 1916, while AFC (Atmosphere
Furnace Company) opened its doors in 1962. In 2000, AFC acquired
Holcroft at which point it became AFC-Holcroft. And most recently,
AFC-Holcroft was acquired in 2016 by the Aichelin Group based in
Austria, whose history goes back more than 150 years.
In a nutshell, that’s a lot of furnaces.
And those furnaces will only become more necessary as the gear
market continues to move into new and exciting frontiers.
“The EV market — electric vehicles — is certainly going to have
an impact on the number and types of gears that we see moving
forward,” Dougherty said. “The industry includes a variety of other
gear manufacturers as well, but automotive — light truck, heavy
truck — is still a very large portion of that. We are already seeing
some of these new higher-RPM gear design specifications and have
successfully run samples using alternative quenching solutions
with great results.”
BIGGER GEARS, TOO
As the number of gears required for the EV market is reduced,
Dougherty said AFC-Holcroft will continue to see growth in other
industries such as wind energy.
“There’s going to be a renewed push for the much larger gears that
we’re going to see in things like wind turbines, as everybody looks at
renewable energy sources and green alternatives,” he said. “I think
that’s going to be something that we see again. In both cases, we’ve
already begun development of some new products to support the
challenges that the gear manufacturers will face in these smaller,
lighter, high-RPM gears for the EV market, as well as very large, deepcase carburized gears for the wind-turbine industry.”
That’s a push that Dougherty especially wanted to drive home:
AFC-Holcroft is committed to a greener future.
“We at AFC-Holcroft, as well as the Aichelin Group as our parent
company, all the way up to their corporate parent company Berndorf
AG — take the reduction of the carbon footprint and the green-energy solution seriously,” he said. “And we’re doing things ourselves
through facility improvements and expansion to greatly reduce our
carbon footprint. There’s also investment in R&D throughout our
corporate structure in areas that we think will have a significant
impact on green-energy solutions for the future.”
is to be involved from the beginning. That includes assisting our
customers with everything from infrastructure to operating costs
and selecting the best solution, which might include multiple options
for them to review and consider.”
MORE INFO
afc-holcroft.com
October 2022 47
PRODUCT
SHOWCASE
NEW PRODUCTS, TRENDS, SERVICES & DEVELOPMENTS
Bantam Tools, the desktop CNC manufacturer, has made some key improvements to its flagship Bantam Tools
desktop CNC milling machine and added the portable Explorer™ CNC milling machine. (Courtesy: Bantam Tools)
Bantam Tools improves
desktop CNC machine,
adds Explorer
Bantam Tools, the desktop CNC manufacturer, has made some key improvements to its
flagship Bantam Tools desktop CNC milling
machine. The improvements, which include
a new black powder coated steel frame, a
deeper chip dish, and tighter pitch on the
Z-axis, are all improvements that help the
machine’s durability and performance, making it a stronger machine built with professional reliability and precision to support
world changers and skill builders.
“After having the Bantam Tools desktop
CNC milling machine out in the market for
a few years, we’ve gotten some good customer feedback on making the machine more
rugged and durable,” said Bre Pettis, CEO of
Bantam Tools. “We’ve taken all of this input
into consideration while revamping the
machine and made it stronger and more
reliable for professional use.”
The Bantam Tools desktop CNC milling
machine offers fourth axis compatibility, 1 ⁄4”
tooling, a 28,000 RPM spindle, a 7” x 9” x 3.5”
build volume and comes with the free version of the Bantam Tools milling machine
software, a 1 ⁄4” ER-11 collet, a 1 ⁄4” flat end
48 gearsolutions.com
mill, a 1 ⁄4” probing pin, right-angle alignment bracket, toe clamp, and aluminum
stock for the tool holder project.
The desktop CNC milling machine is a
proven prototyping solution and is a great
desktop tool for engineers, designers, manufacturers, and those who need reliable prototyping and design capabilities.
These new updates to the Bantam Tools
desktop CNC milling machine also make the
frame more scratch-resistant, hold up better
to daily wear and tear, and the deeper chip
dish allows longer running without needing
to stop and clean out the chips.
Bantam Tools has also launched a new
desktop CNC machine, the Bantam Tools
Explorer™ CNC milling machine. The
machine weighs less than 50 pounds and
is designed with power and portability in
mind with a durable exoskeleton and the
ability to run on battery power.
“We are loving the portability of our
new Bantam Tools Explorer CNC milling
machine,’” said Pettis. “Many product developers and engineers have expressed that
they would love the opportunity to travel
with our machine and put it through its
paces in locations other than their office. We
decided to take on that challenge and have
spent the last year engineering a machine
with expeditionary capabilities that will
meet their needs. Now, when an engineer or
designer needs to be out in the field or working remotely, they can fabricate parts and
solve problems, then easily put the machine
away when they are done.”
With a compact footprint, the new
Bantam Tools Explorer CNC milling
machine fits into a Pelican case and is the
perfect traveling companion for those who
need to mill anywhere. In fact, the machine,
which runs on standard 110V (US) or 220V
(EU) power, can even plug into a generator or
battery power station and is frontline-ready
for users who need to fabricate parts immediately. Additionally, the mill’s compact footprint makes it an ideal solution for engineers
and product designers with hybrid or remote
work schedules, making it a great addition
to Bantam Tools existing desktop offerings
and rapidly expanding ecosystem.
The new powerful and portable Bantam
Tools Explorer CNC Milling Machine features
a powerful modular spindle with ER-11 collet, a rigid unibody exoskeleton, and has the
ability to machine precise aluminum parts
using high-speed machining strategies with
1/4” tooling. Combined with Bantam Tools
pro-grade, easy-to-use machine control software, users will have everything they need
to build the future they want to see and solve
our world’s most pressing challenges.
MORE INFO www.bantamtools.com
Fluoramics’ LOX-8
Grease Now available
in new thickness
Fluoramics’ popular LOX-8 Grease is now
available in a new grade, adding to the diversity of uses.
The original formula of LOX-8 Grease is
an NLGI Grade 00. Fluoramics has now added
a NLGI Grade 2 to round out its offerings.
NLGI grades are established by The
National Lubricating Grease Institute (NLGI)
as standard classifications for lubricating greases. The NLGI consistency number
(sometimes called “NLGI grade”) expresses a
measure of the relative hardness of a grease
used for lubrication. The higher the NLGI
number, the firmer/thicker the grease. The
NLGI consistency number alone is not suf-
Fluoramics’ LOX-8 Grease is available in NLGI 00
and NLGI 2 thickness. (Courtesy: Fluoramics)
ficient for specifying the grease required by
a particular application. Always refer to the
owner’s manual for the recommended type
of grease.
NLGI Grade 00 greases are for use in low
viscosity applications such as ball valves,
f lange gaskets, metal-on-metal contact,
robotics slides which use enclosed gear
drives operating at low speeds, and open
gearing.
Fluoramics’ LOX-8 Grease NLGI 2 is a
multipurpose grease for oxygen and harsh
chemicals in industrial applications. Grade
2 grease is an excellent lubricant for plain
and antifriction bearings operating under
moderate load and at medium speeds. NLGI
Grade 2 grease reduces friction and wear in
high-speed, high-temperature components
like wheel bearings and electric motors.
LOX-8 Grade 2 grease is an excellent grease
for agricultural equipment, chlorine and
sulfuric acid pumps and other high-speed
applications.
LOX-8 Grease is a PCTFE/PTFE grease.
LOX-8 Grease is different than most greases
because it is resistant to harsh chemicals
such as chlorine and powerful oxidizers. It
provides superior performance as a lubricant and is stable from minus-400°F (minus240°C) to 550°F (288°C). It is non-migrating,
non-flammable, non-toxic, non-hardening,
and is anti-galling with stainless steel.
LOX-8 Grease is a high-density lubricant
expressly designed for severe high-pressure
applications. It is also fire resistant, oxygen- approved, and Grade 00 meets MIL-PRF27617G specifications plus is NSF-approved.
“In talking with our customers, we
learned there is a need for both NLGI 00 and
2 of a superior chemical- resistant grease. We
are thrilled to now offer oxygen-safe LOX-8
Grease in both grades,” said Gregg Reick,
Fluoramics’ president and chief chemical
engineer.
MORE INFO www.fluoramics.com
Ceratizit showed off
its MaxiMill 251
milling system at IMTS
To efficiently rough and finish medium to
large part surface areas, Ceratizit USA Inc
showed its universal MaxiMill 251 indexable carbide insert freeform milling system
at IMTS. While well suited for any application and machining strategy, the MaxiMill
excels in multi-axis machining of challenging part contours such those found on turbine blade airfoils.
Within the MaxiMill 251 system is a wide
range of tools and inserts. Those include
CTCS245 and CTC5240 coated carbide insert
grades. CTCS245 is for machining nickelbased alloys, and the CTC5240 grade makes
easy work of cutting titanium.
Using a universal button insert system,
the MaxiMill cutter bodies position inserts
in a positive orientation. This ensures
exceptionally smooth cutting and reduces
cutting forces, especially in unstable workpiece situations.
Part of the Ceratizit Group, Ceratizit
USA designs and manufactures high quality standard and custom tooling for the
metalworking industry. With headquarters
CUSTOM ENGINEERING,
PROTOTYPE WORK, PRECISION
MACHINING, ASSEMBLIES AND
STANDARD COMPONENTS
Gears, pulleys, shafts,
bearings, couplings,
fasteners, custom
gear boxes
ISO9001:2015 & AS9100D,
ITAR Registered, NIST.SP800-171R1,
Trace Certified,
Class 100 clean room
Nordex.com I Sales@nordex.com I Eng@nordex.com
800-243-0986 I 203-775-4877
October 2022 49
PRODUCT
SHOWCASE
and by the new duplex cable via the proven
MarConnect data management software. It
also allows the transmission of a measuring device ID to ensure the traceability of
all measurement results. For measurement
reports, users can choose between complete
representations in PDF format, sending individual measured values to a PC, Bluetooth
printer ,or saving as a TXT file.
MORE INFO www.mahr.com
KISSsoft tackles
manufacturing deviations
and flank waviness
Within the Ceratizit MaxiMill 251 system is a wide range of tools and inserts. (Courtesy: Ceratizit USA)
in Schaumburg, Illinois, Ceratizit USA is a
solutions and service provider for many different industry segments, including automotive, aerospace, and energy. With a highly
specialized staff, expansive product portfolio and an International Traffic in Arms
Regulations (ITAR) registration, Ceratizit
USA provides manufacturers with the complete application engineering, service and
training support needed for maximum productivity and cost-effectiveness.
MORE INFO www.ceratizit.com
Mahr Inc. unveils highly
precise, intuitive height
measuring device
Mahr Inc., a leading provider of dimensional metrology solutions, introduces its new
Digimar 817 CLT height measuring device,
offering an intuitive touch screen, ergonomic handling, and a wide range of evaluation
options. The new gage is available in three
measuring ranges: 350 mm, 600 mm, and
1,000 mm, with multiple logging and data
transfer options for easy measurement data
processing.
50 gearsolutions.com
The touch display ensures that the new
Digimar 817 CLT can be operated as easily
as possible. Large buttons, clearly structured
menus, and self-explanatory icons enable
fast, fluid use and accelerate the measurement cycle. Side function keys and thumbwheel allow the measuring probe to be
quickly positioned for fast simple measurements. Handles on both sides and the integrated air bearing guarantee that the device
can be moved precisely and effortlessly on
the measuring plate.
The touchscreen works similarly to
smartphones and tablets. Keys are arranged
so that frequently used functions are read
for easy access. Measurements can be started conveniently via the touch display, the
thumbwheel with integrated arrow keys or
by manually moving the measuring slide.
Two pushbuttons for operating the air bearings are integrated into the handle and
enable safe and sensitive guidance of the
instrument for left- and right-handed users.
And the swivel mounted touch display can
be rotated or tilted as desired so it’s always
at eye level with the user, whether sitting
or standing.
The new Digimar 817 CLT provides a variety of interfaces for saving measurement
data. Data transfer is possible both wirelessly
With the help of KISSsoft, the user can now
estimate the influence of manufacturing
deviation on the resulting transmission
error and excitation force.
For the form deviations in the profile or
flank line direction, a sinusoidal wave is
applied to the theoretically ideal tooth flank.
The waviness can be modified by amplitude,
length, and phase shift. By specifying an
additional angular deviation, the total deviation is simulated.
These deviations can be executed in
the profile direction, the width direction,
or combined. The result is a change in the
transmission error, excitation force, and
other significant influences on vibration
excitation. The user can thus test how
sensitively a theoretically specified tooth
flank modification reacts to manufacturing deviations.
MORE INFO www.kisssoft.com
KISSsoft users can now estimate the influence of
form deviations and excitation force. (Courtesy:
KISSsoft)
overview of their entire process chain with
WPT 1+. Shops also can change job priority
orders at any time for increased flexibility.
WSM reduces the risk of human error and
increases production-stability processes.
GF Machining Solutions is a leading provider of machine tools, diverse technical
solutions, and services to manufacturers
of precision molds and tooling and of tighttolerance, precision-machined components.
Key segments served include the aerospace,
automotive, medical, energy, information
IMTS 2022 attendees in search of highly flexible workflow automation found solutions
for milling, EDM, wire-cutting EDM, and
laser micro machining applications from
System 3R during the show. One of which
was the System 3R WorkPartner 1+ (WPT 1+)
modular automation system that can more
than double annual production capacity
while conserving valuable shop floor space
and maximizing magazine capacity to load
and unload parts and electrodes.
In EDM applications, WPT 1+ puts a load
station and a drain station in less than 43
square feet (4 square meters) of floor space.
With the WPT 1+, shops can start with a
single magazine unit and add more as production needs change. The various system
models easily serve one or two machines
within in a production cell, with flexible
magazine capacities and variants (light,
heavy or rotary magazines), along with fully
integrated pneumatic control for gripping
devices and table chucks. Large doors allow
for fast and easy loading and unloading to
shorten changeover cycle times for low and
high-volume applications.
For user-friendly WPT 1+ cell management, GF Machining Solutions offers
its WorkShopManager (WSM) software.
Operators can enter cell data quickly in a
structured manner and gain a quick, precise
MORE INFO www.gfms.com
The
Power
of One2
The System 3R WorkPartner 1+ (WPT 1+) modular
automation system that can more than double annual
production capacity while conserving valuable shop
floor space and maximizing magazine capacity to
load and unload parts and electrodes. (Courtesy: GF
Machining Solutions)
GF Machining Solutions
showcases modular
machining automation
and communications technology (ICT), and
electronics industries. An extensive portfolio ranges from electrical discharge machining (EDM) solutions, 3- and 5-axis milling
machines and spindles, 3D laser texturing
machines, additive manufacturing and
machines for laser micromachining to solutions for tooling, automation, software, and
digitalization — all backed by quality customer services and support.
Your Objective:
One face in perfect alignment with another. For infinity.
No problems. No distress. No delays.
That’s the same objective you have for choosing your gear producer.
Circle Gear’s objective is to engage with every customer’s objectives.
One to 1000 gears
Customer designed or reverse engineered
Gearbox repair, rebuild or redesign
OEM or end-users
ISO 9001:2015 Certified
1501 S. 55th Court, Cicero, IL 60804
(800) 637-9335
(708) 652-1000 / Fax: (708) 652-1100
sales@circlegear.com
www.circlegear.com
Spiral and Straight Bevel Gears (Cut, Ground or Lapped) • Spur Gears • Helical Gears •
Long Shafts • Herringbone Gears • Involute and Straight Sided Splines • Internal Gears •
Worm and Worm Gears • Racks • Sprockets • ISO Certified
Partnering with QualityReducer to provide
Gearbox repair, rebuilding and reverse-engineering.
October 2022 51
MARKET
PLACE
Manufacturing excellence through quality, integration,
materials, maintenance, education, and speed.
Contact Gear Solutions at 800-366-2185 to feature your business in the Marketplace!
MAXIMIZE YOUR EXPOSURE
JOIN THE GEAR SOLUTIONS
COMMUNITY
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FOR ONLY
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PER YEAR
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FELLOWS
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SHAPERS
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Site Service:
Emergency & Scheduled
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& Scheduled
Technical
Support:Emergency
Via Telephone,
Fax or E-mail
Training:
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Set-up
& Maintenance
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Maintence Plan: Customized to Your Needs
& Mechanical)
Parts:
New and/or
Used Plan: Customized to Your
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Maintenance
Retrofi
ts - Counters, Servo Controllers, or Single and
Needs
Multiple
Parts: Axis
New CNC
and/or Used
Hydrostatic Guides: Repair Service or Purchase New
Retrofits: Counters, Servo Controllers, or Single and
Multiple
Axis CNC
Allen
Adams
Hydrostatic
Guides: Repair
SHAPER
SERVICES,
Inc.Service or Purchase New
The Voice of Manufacturing
every Tuesday
www.mfgtalkradio.com
with
Lewis Weiss
ALLEN
174
InnovationADAMS
Drive N. SHAPER SERVICES, INC.
Clarendon,
VT 05759
174 Innovation
Drive • North Clarendon, VT 05759
Telephone:
802-226-7891
Telephone:
802-226-7891
E-mail:
shaperservices@shaperservices.com
E-mail:
shaperservices@sharperservices.com
Website:
www.shaperservices.com
Website:
www.sharperservices.com
GEAR RACKS
& GEARS
American and Metric Standards
Straight and Helical
Fine and Course Pitch
Hard-cut and Soft-cut
Precision Quality to AGMA 12
Prototype and Production Quantities
Unique Tooth Configurations
Call 847-447-3430 for a free quote!
INNOVATIVE RACK & GEAR
is now part of
3999 25TH AVE. • SCHILLER PARK, IL 60176 • 847-447-3430
www.gearracks.com • www.aversmachine.com
52 gearsolutions.com
and
Tim Grady
GET CUSTOM-MANUFACTURED
Connect your company to the gear industry
with a storefront in the Gear Solutions
Community. Storefronts paint a portrait of your
company with a 500-word description and
include your logo, website link, phone number,
email addresses, and videos.
For information on how you can participate in the GearSolutions.com
community storefront, contact dave@gearsolutions.com.
Dave Gomez – national sales manager
800.366.2185 x 207
MicroGear
MicroCheck
An uncompromisingly versatile
Gear Analyzing Software System
Turn your existing manual gear tester of any make
or model into a computerized gear analyzing system.
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Phone: +1 909 590 4327 • Fax: +1 909 590 8784
www.MicroGear.us • info@MicroGear.us
ADVERTISER
INDEX
CONTENTS
PAGE NO.
Allen Adams Shaper Services ................................................................52
All Metals & Forge Group................................................................ 11, 52
American Clean Power...........................................................................35
Atlas Bronze...........................................................................................3
Avers Machine and Gear........................................................................52
B&R Machine and Gear.........................................................................19
GET
CONNECTED
Circle Gear & Machine...........................................................................51
Involute Gear & Machine.......................................................................15
KHK-USA...............................................................................................1
KISSsoft USA LLC................................................................................17
MicroGear.............................................................................................52
Nidec Machine Tool America................................................................. BC
New England Gear...................................................................................7
GearSolutions.com is your
trusted online source for
information and technical
knowledge about the gear
manufacturing industry,
getting more than 42,000
page views each month.
Nordex.................................................................................................49
Oelheld................................................................................................13
Piselli Enterprises Inc.............................................................. 55, 56, IBC
Solar Atmospheres...............................................................................IFC
Southern Gear & Machine........................................................................9
STD Precision Gear & Instrument Inc.....................................................13
STLE: Society of Tribology & Lubrication Engineers.................................25
The Broach Masters Inc...........................................................................5
Get your FREE subscription, plus our online
content, at www.gearsolutions.com
Wickert USA.........................................................................................19
October 2022 53
Q& A
INTERVIEW WITH AN
INDUSTRY INSIDER
SCOTT KNOY
VICE PRESIDENT OF SALES 
NIDEC MACHINE TOOL AMERIC A, LLC
“The hobbing process is responsible for the majority of
green cutting in the gearing world; the HS model really
takes hobbing to the next level.”
You recently returned from IMTS. What kind of reactions did you
get from attendees visiting Nidec (formerly Mitsubishi Machine
Tool Division)?
We saw many people that were just happy to be out; however, many
were enthused to see the new technology, and we used the time during the pandemic to develop these new technologies and processes.
The attendance was very good considering the recent situation. We
are seeing many companies and people with real needs and active
projects, and I am certain that they will all be contacting us in
the future.
One of the machines Nidec had on display
at IMTS was the HS series. What makes
the HS series a game changer?
The hobbing process is responsible for most
of the green cutting in the gearing world.
The HS model really takes hobbing to the
next level. We built this machine on a solid
casting for stiffness, rigidity, and thermal
stability. We are using absolute encoders and
linear scales on every axis while each spindle
is outfitted with a very high-speed direct
drive motor. At the show, we were showing
dry cutting with a carbide hob running at
700 surface-feet per minute. This is exceptionally fast.
Most carbide applications are between
300 and 450 surface-feet per minute. In current testing in Japan, we are using this machine to test speeds up
to 1,500 surface-feet per minute. These are speeds that have never
been seen before in the market. Nidec is producing the next level of
productivity and quality in gear hobbing,
and external gearing, making it a game changer.
Anything else about these machines that make them unique
among the competition?
As we discussed, the HS series is pushing the envelope in a very
mature process, and — in a way — making it new again, where our
competition does not appear to be moving forward in this technology.
We know that Nidec is the leader in hobbing technology globally. The
ZI20A was designed from the ground up to be exceptionally thermally stable and robust. We combine this
machine design with the use of the state-ofthe-art abrasive tooling to perform this internal grinding. It is a CBN Dressable wheel, and
the special geometry required to complete
this process has been patented. It just does
an outstanding job making the process less
expensive and faster than one might think,
while producing an excellent gear.
What’s been the industry reaction to some
of Nidec’s newer offerings?
The market is excited about our new technologies and products. We will continue
demonstrating our technology at exhibitions like IMTS, AMB, and JIMTOF, as well as
at our facility or the customer’s facility to
show we are pushing to develop and launch
top level technologies to the gear market.
Nidec is aggressive, and I know you are going to see many more
innovative Nidec products introduced to the market that offer cutting edge technologies. Nidec is a technology company; we operate
at an exceptionally high level, and people are excited to see it.
What other machine models offered by Nidec should the industry
be on the lookout for?
Anything else on the horizon that Nidec is working on that you’d
like to share?
I feel that our ZI20A internal gear grinder is the next big thing that
you are going to see in the market. Our ZI20A is the only internal gear
grinder that uses a generating method for finishing the gear. What
this means for the customer is faster and more accurate production
than what you will find in the world of honing or in the world of
form grinding. As you know, EV applications are subject to very rigid
NVH testing, and the ZI20A is able to hard finish these internal ring
gears and correct the pitch errors, which drive the NVH issues. We
had been involved in a study with FEV, and it was determined that
pitch error was the leading cause of NVH issues in electric vehicles.
Our machine is able to eliminate this error and to produce a much
quieter, more robust gear. The flexibility of this machine also makes
it possible to grind external gears, where clearance is an issue. The
flexibility this machine offers makes it possible to grind internal
We have developed a cut-chamfer machine. I know a few others
also have it. The Nidec model is the CF260, and it will debut at
the JIMTOF show in November. It has been cutting parts for a few
months and will be set up for that show. There are several other
initiatives underway but that are not ready for release yet. I can
tell you, based on our discussions and based on what we have been
seeing, EV is becoming a bigger part of the market, and you can
be sure that hard gear finishing will take a prominent role in our
future developments. I really can’t tip our hand, but I can tell you
hard gear finishing is the future.
54 gearsolutions.com
MORE INFO
www.nidec-machinetoolamerica.com
THE #1 SOURCE FOR
USED GEAR MACHINERY
At Piselli Enterprises, we not only offer quality gear machinery, but also
offer the following services:
BROKERING EQUIPMENT
We help customers sell their surplus machinery
and equipment for a commission.
TECHNICAL ASSISTANCE
We can source the proper technical assistance for
your particular gear machine needs.
TRADE-INS
We take trade-in machines against the purchase of
our selection of machines and equipment.
PARTS CONSULTING
We can help you assess your equipment needs for
a particular project, as well as offer competitive
alternatives. Call 704-609-0766 or email
rich@pisellient.com.
2007 Kapp KX-300P CNC Gear Grinder
1992 Fellows Model 100-12 CNC Gear Shaper, 12” stroke, 83” table with outriggers
325 N Miller Ave Statesville, NC 28677
704.609.0766 • rich@pisellient.com
www.pisellient.com
1999 Gleason Pfauter Model P400G CNC gear grinding machine 400mm diameter capacity
2003 Liebherr Model LC-282 CNC Gear Hobber w/ auto loading dry or wet cutting LH 90 controls
MEMBER
THE #1 SOURCE FOR USED GEAR
MACHINERY — AND MORE!
October 2022 55
MEMBER
Contact us to add your surplus machinery
2010 Gould & Eberhardt Model 120-GH 3 Axis CNC Gashing Machine, 150” Diameter
2005 Liebherr Model LC-80 CNC Gear Hobber
Barber Colman Model 16-56 extended w/ 48” arm extension
2006 Mitsubishi Model SE25A CNC Gear Shaper
Fellows Model 10-4 CNC 3 axis Gear Shaper
w/ Fanuc Controls
2006 Gleason M&M systems Sigma 3,
12” diameter CNC gear testing machine
325 N Miller Ave Statesville, NC 28677
704.609.0766 • rich@pisellient.com
56 gearsolutions.com
www.pisellient.com
1995 Gleason Model Tag 400 CNC generating
style Gear Grinder 400mm capacity
Fellows model 645A5 Gear Shaper, 14” riser,
cutter elevation, 5” hole in table
Bourn & Koch Model 25H 4 axis CNC
Horizontal Gear Hobber
2007 Fellows MS 450-650/125 6 axis
guideless CNC Gear Shaper
THE #1 SOURCE FOR USED GEAR
MACHINERY — AND MORE!
Contact us to add your surplus machinery
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MEMBER
2019 Klingelnberg Viper 500W
CNC Gear Grinder
1990 Barber Colman Model 14-15
Gear Hobber
2015 Fellows Model 10-4 CNC 3 axis Gear Shaper
2005 Kashifuji Model KN80 6 axis CNC Gear Hobber, Fanuc controls
Heckert Model ZFWVG 250 x 2000, 19” Diam x 80”
cut length horizontal hobber with differential
Pfauter Model P-500 Vertical Gear Hobber, 20”
max diameter, worm drive head differential
2000 Mitsubishi Model GN20A 5 axis
CNC Hobber, Fanuc 18i controls
325 N Miller Ave Statesville, NC 28677
704.609.0766 • rich@pisellient.com
www.pisellient.com
Gleason Model 350 GMM CNC Gear Testers,
updated software 2016 & Renishaw probes
Gleason Model 600 HTL Turbo Lapper , Fanuc
160I-M control new 2000
2005 Gleason Model Phoenix 125GH CNC
6-axis Gear Hobber, 180-position loaders
Fellows Model 36-8 12” Riser Cutter
Elevating Gear Shapers
THE #1 SOURCE FOR USED GEAR
MACHINERY — AND MORE!
Contact us to add your surplus machinery
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